Composite Winding Core with Expandable Bladder Shaft
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Solution Overview
Problem
Existing winding cores are heavy, expensive, and lack the necessary strength, durability, and manufacturing efficiency to meet high-performance demands.
Innovation Solution
The development of novel winding cores made from engineered FRP materials, featuring a lightweight, strong, and durable design with a method using an expandable bladder to secure a shaft within the core, allowing for rapid material winding and easy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional paper or fiberglass laminated with phenolic resin is used to manufacture winding cores, then the cores provide sufficient strength and durability, but they are heavy and expensive
Solution Approach 1:
The patent applies composite materials by combining fiberglass reinforcement with polyester resin to create a winding core that achieves both reduced weight and maintained strength. The fiberglass provides structural integrity while the polyester resin matrix binds the fibers together, creating a lightweight yet strong composite structure that replaces the heavier traditional phenolic resin laminates
2Productivity
If traditional winding core manufacturing methods are used, then the cores are durable, but they are expensive and time-consuming to manufacture
Solution Approach 1:
The patent applies segmentation by dividing the winding core into two separate elongate bodies that are manufactured independently and then joined together. This segmentation allows each half to be manufactured separately using efficient composite layup techniques, reducing overall manufacturing time and complexity compared to traditional methods while maintaining durability through the bonded joint
3Weight of moving object
If continuous tube design with bonded and pinned ends is used, then the cores provide structural integrity, but they are heavy and difficult to manufacture quickly
Solution Approach 1:
The patent divides the continuous tube into two elongate bodies joined at their midfaces, creating a segmented structure that reduces weight while maintaining structural integrity through the bonded joint. This segmentation allows for more efficient manufacturing of lighter components that can be assembled quickly
Solution Approach 2:
The patent introduces an axial joint between two elongate bodies, adding a new dimensional approach to core construction. Instead of a single continuous tube, the core is built by joining segments along its length, enabling lighter construction while preserving structural performance through the midface bonding interface
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
The new winding cores are lighter, easier to manufacture, and more cost-effective than existing technologies, while providing enhanced strength and durability, making them suitable for high-performance applications.
Implementation Method 1
The bladders are expanded and consequently secure the shaft to the bore
Implementation Method 2
an adhesive resin or bonding agent such as epoxy is used during manufacture to secure the outer radial face of the inner axle support to the inner face of the outer radial wall
Data Source
AI summary
A high performance and lightweight composite industrial winding core for winding a thin material stock thereon. In preferred embodiments, the winding core is engineered from fiber reinforced plastic and comprises a pair of elongate winding core bodies aligned along an axis having a generally cylindrical outer face with an inner face that defines the inside of the hollow cylinder. A first end wall and a second end wall enclose the ends of the winding core. A series of spaced axle supports support the winding core bodies. An inner axle face engages with an axle shaft. Portions of the winding core can be joined by an adhesive resin or bonding agent. The axle shaft can include inflatable bladders and can engage an inner tube of the winding core. A method for using a winding core to wind material stock is disclosed.