Convolute Tube Composite Sheet Adhesion
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Solution Overview
Problem
Conventional convolute tube production methods are limited by the length of the winding machine, leading to inefficiencies and increased production costs due to the need for skiving, which results in hazardous dust waste and reduced material strength.
Innovation Solution
A convolute tube is formed using a composite sheet material comprising a primary sheet and a fixation sheet of different thicknesses, where the fixation sheet is overlapped onto the primary sheet to create a lap seam, allowing for secure adhesion and reduced material loss during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional winding machines cut paper sheet to length corresponding to machine limitations, then tube production can proceed, but production efficiency decreases and production costs increase
Solution Approach 1:
The paper sheet is divided into multiple separate sheets (first sheet, second sheet, third sheet) that can be processed independently and then assembled. This allows the winding machine to work with shorter, manageable sheet lengths while still producing long tubes through the assembly of multiple segments, thereby overcoming the machine length limitation and improving production efficiency.
Solution Approach 2:
The separate sheets are prepared and positioned in advance before the winding process. The first sheet is wound and secured, then the second and third sheets are pre-positioned to be subsequently wound and connected. This preliminary preparation enables continuous production without stopping the winding machine, reducing production time and increasing efficiency.
2Reliability
If skiving is applied to paper sheet edges to improve adhesion, then trailing edge can be secured, but hazardous dust waste is generated and material strength is reduced
Solution Approach 1:
The harmful skiving process is completely removed from the production method. Instead of cutting or skiving the paper edges to create adhesion surfaces, the invention uses intact paper edges that are directly overlapped and secured with adhesive. This eliminates dust generation while maintaining reliable trailing edge adhesion through the lap seam connection.
Solution Approach 2:
The invention uses a disposable adhesive layer instead of mechanical skiving. The adhesive is applied to the paper surfaces and provides sufficient bonding without requiring material removal. This approach is cleaner, generates no hazardous dust, and maintains the full strength of the paper material.
3Reliability
If skiving is used to prepare paper edges for adhesion, then trailing edge can be fixed, but material strength is reduced
Solution Approach 1:
A layer of adhesive is used as a temporary bonding agent that provides sufficient fixation strength without compromising the underlying paper material. The adhesive is applied to the overlapping edges and dries to form a strong bond, preserving the full structural integrity and strength of the paper sheets while ensuring reliable trailing edge fixation.
Solution Approach 2:
The paper sheets are joined using a composite bonding approach where adhesive material is introduced between the paper layers. This creates a composite structure of paper-adhesive-paper that maintains the strength properties of the paper while providing reliable adhesion at the trailing edge through the bonding interface.
4Device complexity
If conventional single sheet winding is used, then production process is simple, but tube length is limited by winding machine capacity
Solution Approach 1:
The tube production process is segmented into multiple winding operations on the same machine. Each sheet (first, second, third) is wound separately to create tube segments, which are then connected by overlapping and adhesive bonding. This allows the production of tubes longer than the machine's single-winding capacity while keeping the winding process itself relatively simple and familiar.
Solution Approach 2:
The winding machine operates continuously without interruption to produce the full-length tube. The first sheet is wound, then immediately followed by winding the second and third sheets in sequence. The overlapping connections are made during the winding process itself, maintaining continuous production flow and eliminating the need for separate assembly operations, thus managing complexity while achieving extended tube 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 method enables high-speed manufacturing with reduced production expenditures and eliminates hazardous dust waste, while maintaining material strength and achieving a smooth exterior surface.
Implementation Method 1
a convolute tube formed of a convolutely wound, adhesively secured composite sheet material
Data Source
AI summary
A convolutely wound tube (1) is formed of a composite sheet including a first sheet (6) and a second sheet (5). The convolutely wound tube includes a first segment (66) formed of a plurality of convolute windings (2) of the first sheet, a second segment (70) formed of directly adhered and overlapping portions of the first sheet and the second sheet, and a third segment (68) formed of the second sheet wrapped about and overlying the first sheet. The second segment is an underwrap portion positioned between a layer of the first sheet and a layer of the second sheet.