Calender Layout Reducing Length via Overlapping Rolls
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Solution Overview
Problem
The existing calender configuration with multiple rolling rolls, a take-off roll, cooling rolls, and a winding roll in a straight line increases the overall length, making it inefficient.
Innovation Solution
The calender design is optimized by positioning the extrusion unit above the first roll unit, allowing the resin material to be kneaded and pressed by the first roll unit, then rolled by the second roll unit positioned further forward, and wound around a roll positioned further rearward, with the first and second roll units partially overlapping, reducing the overall length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rolling rolls, take-off roll, cooling rolls, and winding roll are disposed in substantially one row, then the resin film can be continuously processed through kneading, rolling, cooling, and winding, but the entire length of the calender becomes excessively long (7 to 9 meters)
Solution Approach 1:
The patent transitions from a one-dimensional linear arrangement to a two-dimensional layout by positioning the extrusion unit above the first roll unit and arranging cooling rolls and winding roll in the rearward direction. This spatial reconfiguration reduces the calender's length from 7-9 meters to approximately 2.5 meters while preserving continuous processing capability
2Length of moving object
If the extrusion unit is positioned above the first roll unit with overlapping roll units, then the calender length is reduced to approximately 2.5 meters, but the resin material must transfer in a U-turn pattern from rear to front and back
Solution Approach 1:
The patent introduces a U-turn transfer path where the resin material moves from rear to front and then back to rear, creating a curved material flow path. This curved trajectory enables compact spatial arrangement while maintaining continuous processing, transforming the linear material flow into a cyclic pattern that fits within the reduced 2.5-meter length
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows the resin material to be formed into a film while transferring from the rear to the front and back, effectively reducing the calender's length from 7 to 9 meters to approximately 2.5 meters, enhancing efficiency and compactness.
Implementation Method 1
The resin material is kneaded by the extrusion unit after being supplied to the material supply port
Implementation Method 2
the resin material is pressurized by the first roll unit
Implementation Method 3
the resin material is rolled by the second roll unit, to the resin film
Implementation Method 4
the resin film passing through the cooling rolls is cooled by a cooling medium which flows inside of the cooling rolls
Data Source
Figure 1
Figure 2
Figure 3~4B
AI summary
A calender 10 includes an extrusion unit 3 which kneads and extrudes a resin material, a first roll unit 5 which pressurizes the extruded resin material, a second roll unit 7 which rolls the resin material from the first roll unit 5, and a winding roll which winds the resin material rolled by the second roll unit 7. The second roll unit 7 is positioned further forward than the first roll unit 5.