Corrugated Substrate Forming with Variable-Speed Flute Control
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Solution Overview
Problem
Conventional corrugation processes are limited by inflexible frequency and amplitude adjustments, high costs due to expensive rollers, difficulty in processing larger amplitudes, and inability to handle materials with low plasticity, such as rubber or certain plastics, which lack the necessary support and water resistance.
Innovation Solution
A method and apparatus that uses upper and lower drive rollers to drive substrates and a middle substrate at varying velocities to form flutes, allowing for adjustable corrugation patterns, adaptable to different materials, and incorporating a bonding device for attaching the middle substrate to the upper and lower substrates, enabling the production of corrugated products with improved strength, water resistance, and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional corrugating rollers are used to mold the medium into waveform, then the medium can be corrugated, but the frequency and amplitude of the wave are not easily adjustable and require roller swapping which causes downtime
Solution Approach 1:
The patent applies dynamics by making the corrugation profile adjustable during operation. Instead of fixed rollers, the system uses a form roller with a variable profile that can be dynamically adjusted to change the frequency and amplitude of the corrugation wave without requiring physical roller replacement, thereby eliminating downtime and improving adaptability.
Solution Approach 2:
The patent implements parameter changes by allowing the form roller profile to be modified to alter the corrugation characteristics. The system can change the geometric parameters of the roller surface to produce different wave frequencies and amplitudes, enabling flexible adjustment without swapping entire roller assemblies.
2Adaptability or versatility
If expensive sets of rollers are used for corrugation, then different frequencies and amplitudes can be achieved, but the cost increases significantly
Solution Approach 1:
The patent applies universality by designing a single form roller that can perform multiple functions by adjusting its profile. Instead of requiring multiple specialized rollers for different corrugation specifications, one universal form roller can be reconfigured to produce various frequencies and amplitudes, significantly reducing the number of expensive rollers needed and lowering overall manufacturing costs.
Solution Approach 2:
The patent uses copying by creating a variable profile on the form roller that can replicate different corrugation patterns. The roller surface can be modified to copy or simulate the effect of multiple different roller profiles, allowing the system to achieve diverse corrugation outputs without investing in multiple physical roller sets.
3Strength
If large amplitude corrugations are required, then the structural support is improved, but the rollers would need to be so big that it becomes cost prohibitive
Solution Approach 1:
The patent applies dynamics by using a form roller with a variable profile that can dynamically adjust to create large amplitude corrugations when needed. Instead of requiring permanently large rollers, the system can modify the roller profile on-demand to generate the necessary wave amplitude, maintaining structural support without the prohibitive cost of permanently large roller assemblies.
Solution Approach 2:
The patent implements parameter changes by allowing the form roller profile to be modified to produce larger wave amplitudes. The system can change the geometric parameters of the roller surface to create more pronounced corrugations, achieving the required structural support through profile adjustment rather than through the use of excessively large and expensive rollers.
4Adaptability or versatility
If materials with low plasticity such as rubber or certain plastics are used, then material versatility is improved, but the materials may not hold their shape after going through corrugating rollers
Solution Approach 1:
The patent applies dynamics by using a form roller with a variable profile that can adapt to the specific properties of different materials. For materials with low plasticity like rubber or certain plastics, the roller profile can be dynamically adjusted to apply appropriate pressure and maintain the corrugated shape, ensuring shape retention while processing diverse materials with varying plasticity characteristics.
Solution Approach 2:
The patent implements parameter changes by modifying the form roller profile to accommodate materials with low plasticity. The system can adjust the roller surface geometry to create more gradual or sustained pressure zones that help materials with low plasticity maintain their corrugated shape after processing, thereby improving shape retention for a wider range of materials.
Data Source
AI summary
The invention describes a device and method for making corrugated products. The device can be used with any substrate and includes, at least, first and second drive rollers for driving a middle substrate and a single wall corrugated product. In other embodiments the invention includes upper drive rollers, lower drive rollers and middle drive rollers for driving an upper substrate, a lower substrate and a middle substrate. The middle substrate is driven between the upper and lower substrates at a higher velocity to form flutes that are anchored between the upper an lower substrates thereby forming a corrugated product. The invention also provides for customized corrugated products having multiple fluted substrates in various desirable arrangements. Examples of such products include mattress, partition panels, other furniture and construction products.