Deformable Support Roller for Thin Film Wrinkle Prevention
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Solution Overview
Problem
Existing rollers fail to prevent wrinkles in thin film materials during manufacturing processes, which are crucial for secondary batteries and other flexible materials.
Innovation Solution
A roller design featuring a rotation shaft, pipe, deforming part, and support part, with thread and nut components that adjust tension by rotating the shaft, using inclined parts to deform the pipe and bobbins to provide flexible support, preventing wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple roller structure is used to support the material, then the device complexity is reduced, but the material surface quality deteriorates due to wrinkle formation
Solution Approach 1:
The roller incorporates a deformable pipe structure that can dynamically adjust its shape through the deforming part. The pipe transitions from a straight configuration to a deformed configuration with varying radius of curvature, allowing the roller to adapt to different material characteristics and prevent wrinkle formation while maintaining operational simplicity
Solution Approach 2:
The roller changes the geometric parameters of its support surface by deforming the pipe. The radius of curvature of the pipe is varied along its length and can be adjusted during operation, enabling the roller to provide optimized support for different material types and tension requirements without increasing overall device complexity
2Device complexity
If a fixed tension roller is used, then the device complexity is reduced, but the adaptability to different material characteristics deteriorates
Solution Approach 1:
The roller transforms from a static structure to a dynamic one through the deforming part mechanism. The pipe can be deformed to different extents and configurations, allowing the roller to adapt to various material characteristics such as flexibility, thickness, and tensile strength, while the overall device structure remains relatively simple
Solution Approach 2:
The roller adjusts key parameters including the radius of curvature of the pipe, the degree of deformation, and the tension applied to the material. These parameter changes enable the roller to accommodate different material characteristics without requiring multiple specialized rollers or complex adjustment mechanisms
3Manufacturing precision
If high tension is applied to prevent wrinkles, then the material surface quality is improved, but the risk of material damage increases
Solution Approach 1:
The roller applies tension and support forces locally through the deformed pipe structure rather than uniformly across the entire material width. The deforming part creates specific deformation zones that concentrate support where needed, preventing wrinkles in critical areas while maintaining lower overall tension to protect material integrity
Solution Approach 2:
The roller dynamically adjusts the tension applied to the material by controlling the degree of pipe deformation. When material characteristics indicate higher risk of damage, the roller reduces deformation and tension; when wrinkle prevention is the priority, the roller increases deformation and tension, thereby maintaining material integrity while ensuring surface 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 roller effectively adjusts tension to match material characteristics, preventing defects like wrinkles and ensuring high-quality production of materials such as electrodes and separators.
Implementation Method 1
a thread portion (180) provided on the rotation shaft (12) and a nut part (182) screwed to the thread portion (180), in which the nut part (182) is pressed by the nut part (182) according to rotation of the rotation shaft (12)
Implementation Method 2
an inclined part (184) that is disposed at an inner surface of the pipe (14) and that is pressed by the nut part (182) according to rotation of the rotation shaft (12), and a support part (16) that is installed at the pipe (14) to support the material (3)
Data Source
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AI summary
A roller for supporting a material according to an embodiment of the present invention includes: a rotation shaft; a pipe having a space in which the rotation shaft is inserted; a deforming part that is connected to the rotation shaft and the pipe to deform the pipe; and a support part that is installed at the pipe to support the material. The deforming part includes: a thread portion provided on the rotation shaft; a nut part screwed to the thread portion; an inclined part that is disposed at an inner surface of the pipe and that is pressed by the nut part according to rotation of the rotation shaft; and a driving source that is connected to the rotation shaft to rotate the rotation shaft.