Corrugated Roller Stretching for Flexible Sheets Without Width Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing flexible sheets using corrugated rollers either compromise sheet strength or result in width reduction and inadequate touch feel due to limitations in roller velocity ratios and engagement depths.
Innovation Solution
A method involving a pair of corrugated rollers with intermeshing ridges, where the peripheral velocity of the first drive rollers is set higher than that of the corrugated rollers, allowing for a larger engagement depth without width contraction, and a controlled tension is applied to achieve a flexible sheet with improved flexibility and touch feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the depth of engagement of the roller ridges is increased to reach a high stretch ratio, then the stretch ratio is improved, but the sheet strength is reduced
Solution Approach 1:
The invention changes the velocity parameter relationship between rollers, setting V1>V2 instead of equal velocities. This parameter change allows the system to achieve high stretch ratios through the velocity differential mechanism rather than relying solely on deep ridge engagement, thereby resolving the contradiction between stretch ratio and sheet strength
Solution Approach 2:
The invention introduces dynamic velocity control where the first drive rollers and corrugated rollers operate at different velocities (V1>V2). This dynamic approach replaces the static deep engagement method, enabling continuous stretching without excessive localized stress that would weaken the sheet
2Productivity
If the rotational velocity of the gear rollers is set high to achieve high stretch ratio processing, then the productivity is improved, but the depth of grooves between ridges cannot be set large enough, resulting in inadequate touch feel
Solution Approach 1:
The invention changes the velocity parameter relationship from equal velocities to V1>V2, which fundamentally alters how stretching is achieved. This allows large groove depths to be used without requiring excessively high rotational velocities, as the stretching is assisted by the velocity differential between the first drive rollers and corrugated rollers
3Productivity
If the sheet is preliminarily stretched by stretching rollers before the gear rollers, then the stretch ratio is improved, but the sheet width is reduced due to added tension in the machine direction
Solution Approach 1:
The invention uses dynamic velocity control (V1>V2) to achieve stretching without the need for preliminary stretching that would tension and narrow the sheet. The velocity differential creates a controlled stretching action that maintains sheet width while achieving the desired stretch ratio
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 method produces a flexible sheet with high flexibility and superior touch feel without significant width reduction, maintaining sheet strength and economic efficiency by optimizing the velocity ratio and engagement depth of the rollers.
Implementation Method 1
the peripheral velocity V1 of the first drive rollers and the peripheral velocity V2 of the corrugated rollers have a relation of V1>V2
Implementation Method 2
a base sheet is fed from between a pair of first drive rollers into the bite between a pair of intermeshing corrugated rollers
Implementation Method 3
a sheet such as nonwoven fabric is introduced into a bite between a counterrotating pair of corrugated rollers each having ridges extending on the peripheral surface parallel to the axis of rotation in intermeshing engagement with each other
Data Source
AI summary
A method for producing a flexible sheet includes a stretching step in which a base sheet (10) is fed from between a pair of first drive rollers (42, 43) into the bite of a pair of intermeshing corrugated rollers (2, 3) and stretched in the machine direction between the corrugated rollers (2, 3). In the method, the peripheral velocity V1 of the first drive rollers (42, 43) and the peripheral velocity V2 of the corrugated rollers (2, 3) have a relation of V1>V2.