Corrugated Profile Guiding Plate for Multi-Layer Material Welding
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Solution Overview
Problem
Existing systems for producing multiple layer materials are inefficient, leading to increased production stops, maintenance requirements, and reduced cost-efficiency in the packaging industry.
Innovation Solution
A system comprising corrugation rolls, press rolls, and heating members with a guiding plate that stabilizes the corrugated profile through cooling and precise alignment, allowing for faster and more reliable production of multiple layer materials by ensuring efficient guidance and welding of the material sheet to the corrugated profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If prior art devices are used for producing multiple layer materials, then the basic welding function is achieved, but the production efficiency is low and production stops occur frequently
Solution Approach 1:
A guiding plate is introduced as an intermediary component between the corrugation rolls and heating members. This guiding plate stabilizes the corrugated profile during transport, preventing deviations that would cause production stops. The plate acts as a mediator that ensures the corrugated profile maintains its positional accuracy throughout the welding process, thereby improving both productivity and reliability.
Solution Approach 2:
The guiding plate performs preliminary stabilization of the corrugated profile before the material reaches the heating members for welding. By pre-positioning and stabilizing the profile, the system prevents potential misalignment issues during welding, reducing production stops and maintaining continuous efficient operation.
2Manufacturing precision
If the corrugated profile is not properly stabilized, then the system structure remains simple, but the guiding precision towards heating members deteriorates
Solution Approach 1:
The guiding plate serves as a simple intermediary structure that provides the necessary guiding precision without significantly complicating the overall system. The plate's straightforward design with crests matching the corrugated profile ensures precise alignment while adding minimal structural complexity.
Solution Approach 2:
The guiding plate utilizes thermal parameters by being cooled to stabilize the corrugated profile. By changing the temperature parameter of the guiding plate, the system achieves precise guiding without requiring complex mechanical adjustment mechanisms, thus maintaining simplicity while improving manufacturing precision.
3Productivity
If production speed is increased without stabilization, then productivity improves, but the reliability of the welding process deteriorates
Solution Approach 1:
The guiding plate acts as a stabilizing intermediary that enables higher production speeds while maintaining welding reliability. By ensuring the corrugated profile remains steadily positioned throughout the process, the plate allows the system to operate at higher speeds without compromising the quality of the welding joint.
Solution Approach 2:
The guiding plate performs preliminary stabilization at high speed, preparing the corrugated profile for welding before it reaches the heating members. This preliminary action ensures that even at increased production speeds, the profile is properly positioned for reliable welding, maintaining both productivity and welding quality.
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 system enhances production speed, reliability, and cost-efficiency by reducing maintenance needs and production stops, while maintaining high precision in guiding and welding the corrugated profile with the material sheet.
Implementation Method 1
a cooling arrangement is provided for cooling the guiding plate
Implementation Method 2
heating members for welding a material sheet to the corrugated profile
Data Source
AI summary
A system for producing a multiple layer material (49), comprising first and second corrugation rolls (14, 15) for providing a corrugated profile (16) having a plurality of crests (47), wherein the system further comprises first and second press rolls (21, 22) for applying a material sheet (19, 20) to crests (47) of the corrugated profile (16), and a plurality of heating members (28) arranged between the press rolls (21, 22) for welding the material sheet (19, 20) to the crests (47) of the corrugated profile (16) to form the multiple layer material (49). A guiding plate (48) is arranged between the corrugation 10 rolls (14, 15) and the heating members (28). The guiding plate (16) is arranged with a profile engaging side (50) having a plurality of crests (52) corresponding to the crests (47) of the corrugated profile (16). A cooling arrangement is provided for cooling the guiding plate (48). A method for producing the multiple layer material (49) is also disclosed.