Corrugated Plastic Conveyor Roller for Lower Noise and Weight
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Solution Overview
Problem
Existing metal rollers used in conveyors are excessively loud and heavy, leading to noise pollution and increased weight in roller systems.
Innovation Solution
A corrugated reinforced plastic roller design featuring a cylindrical outer layer, corrugated plastic filling with a hollow center, and multiple reinforcement layers, which includes a honeycomb, bubble, or rectangular reinforcement structure, to provide lightweight and noise-dampening properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal rollers are used in conveyors, then structural strength is ensured, but weight increases and noise levels become excessively high
Solution Approach 1:
The roller employs a composite structure combining plastic outer layer with corrugated plastic filling (honeycomb, bubble, or rectangular reinforcement structures). This composite design provides sufficient structural strength while significantly reducing weight compared to solid metal rollers, achieving a 50-100% increase in flexural strength-to-weight ratio.
Solution Approach 2:
The reinforcement layers are strategically positioned within the roller structure, with corrugated plastic filling concentrated in specific zones to provide localized strength where needed. This allows weight reduction in non-critical areas while maintaining structural integrity in load-bearing regions.
2Strength
If metal rollers are used in conveyors, then structural strength is ensured, but noise levels become excessively high
Solution Approach 1:
The invention changes the material parameters from metal to plastic, fundamentally altering the acoustic properties. Plastic materials have different damping characteristics that reduce noise generation and transmission, achieving a 10-30% reduction in noise levels while maintaining structural strength through the corrugated reinforcement design.
Solution Approach 2:
The multi-layer composite structure with corrugated plastic filling creates acoustic damping through the layered construction and air pockets, reducing noise transmission while maintaining mechanical strength.
3Weight of moving object
If corrugated plastic filling is used, then weight is reduced and noise is dampened, but manufacturing complexity increases
Solution Approach 1:
The roller is divided into distinct segments: outer layer, reinforcement layers, and corrugated plastic filling. This segmentation allows each component to be manufactured separately using optimized processes and then assembled, reducing overall manufacturing complexity despite the multi-layer structure.
Solution Approach 2:
The corrugated plastic filling is available in standardized forms (honeycomb, bubble, rectangular structures) that can be directly inserted into the roller assembly, eliminating the need for complex in-situ formation processes and simplifying manufacturing.
Data Source
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.