Corrugated Reinforced Plastic Roller for Conveyor Noise Reduction
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Solution Overview
Problem
Existing metal rollers used in conveyors are heavy and produce excessive noise during transportation, leading to inefficiencies and increased weight in roller systems.
Innovation Solution
A corrugated reinforced plastic roller design featuring a cylindrical outer layer wrapped around a corrugated plastic filling with reinforcement layers and surface treatment, providing a lightweight and noise-reduced solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal rollers are used in conveyors, then strength and durability are improved, but weight increases and noise levels increase
Solution Approach 1:
The roller employs a composite structure combining plastic outer layer with corrugated plastic filling and reinforcement layers. This composite material approach achieves the required strength and durability while significantly reducing weight compared to solid metal rollers, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The roller features a nested multi-layer structure where the outer plastic layer envelops the corrugated plastic filling, which in turn contains reinforcement layers. This nested configuration optimizes strength distribution while minimizing material usage and weight, addressing both strength requirements and weight reduction goals.
2Reliability
If metal rollers are used in conveyors, then durability is improved, but noise levels increase
Solution Approach 1:
The invention changes the material parameter from metal to plastic, fundamentally altering the noise generation characteristics. Plastic material inherently produces lower noise levels during operation while maintaining durability through the reinforced composite structure, thus resolving the contradiction between durability and noise reduction.
Solution Approach 2:
The composite construction with multiple layers including corrugated plastic filling provides both durability and noise reduction. The layered composite structure absorbs vibrations and reduces noise generation while maintaining the mechanical strength required for durable operation.
3Use of energy by moving object
If roller weight is reduced, then energy efficiency is improved, but structural strength may deteriorate
Solution Approach 1:
The composite material construction achieves optimal strength-to-weight ratio. The plastic-based composite structure provides sufficient structural strength for conveyor applications while being significantly lighter than metal alternatives, thereby improving energy efficiency without compromising strength.
Solution Approach 2:
The corrugated structure introduces a dimensional element with its wave-like pattern, creating geometric reinforcement that enhances structural strength without adding proportional weight. This dimensional feature optimizes the strength-to-weight ratio for improved energy efficiency.
Data Source
Figure 1
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AI summary
An example roller is provided. The example roller can include an outer layer having a cylindrical shape, wherein the outer layer extends between a first end and a second end. The example roller can include a first bearing disposed at the first end. The example roller can include a second bearing disposed at the second end. The example roller can include a corrugated plastic filling, wherein the outer layer is wrapped around the corrugated plastic filling.