Composite Metal Roller Reinforcement for Lower Noise and Weight

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Solution Overview

Problem

Existing metal rollers used in conveyors are heavy and produce excessive noise during transportation, which are significant drawbacks in terms of weight management and noise reduction.

Innovation Solution

A reinforced metal roller design that incorporates a metal tube with a reinforcement filling made of non-metal materials, such as corrugated plastic or silicone-based powder, which is placed between the bearings and the motor, if present, to reduce weight and noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal rollers are used for conveyor applications, then strength and durability are improved, but weight increases and noise is excessive

Engineering Contradiction:

Improveroller strengthVSAvoidroller weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The roller employs a composite structure consisting of a metal tube outer layer providing strength and durability, combined with a plastic core material (such as polypropylene or polyethylene) that reduces weight. This composite material approach allows the roller to maintain structural integrity while significantly reducing overall weight compared to solid metal rollers.

Inventive Principle:

Principle #40Composite materials

2Strength

If metal rollers are used for conveyor applications, then strength and durability are improved, but noise during transportation becomes excessive

Engineering Contradiction:

Improveroller strengthVSAvoidnoise

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The composite structure with plastic core material inherently reduces noise generation during operation compared to solid metal rollers. The plastic material provides noise dampening properties while the metal tube outer layer maintains strength requirements.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The plastic core material may incorporate a porous or cellular structure (such as foam or honeycomb pattern) that provides both weight reduction and noise absorption capabilities. The porous structure helps dampen vibrations and reduce noise during conveyor operation.

Inventive Principle:

Principle #31Porous materials

3Strength

If reinforcement filling is added to the metal tube, then flexural strength is improved, but device complexity increases

Engineering Contradiction:

Improveflexural strengthVSAvoidroller structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The reinforcement filling creates a composite structure where the plastic material is embedded within or alongside the metal tube. This composite approach enhances flexural strength by combining the rigidity of metal with the reinforcement properties of the plastic filling, while the integration process is designed to minimize manufacturing complexity.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4495031A1Reinforcement to reduce noise and improve flexural strength for metal rollers

Publication Date: 2025.01.22 INTELLIGRATED HEADQUARTERS LLC

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AI summary

A roller (100), comprising a metal tube (110) extending between a first end and a second end, wherein the metal tube (110) comprises an outer surface and an inner surface; a first bearing (120) disposed at the first end; a second bearing (130) disposed at the second end; and a reinforcement filling (210) in contact with the inner surface of the metal tube, wherein the reinforcement filling is made at least partially of a non-metal material.