Film Processing Apparatus with Automatic Scraping Mechanism Adjustment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing film processing apparatuses are inefficient in adapting to films of different materials, thicknesses, or softnesses, requiring lengthy debugging periods and manual adjustment, which reduces production efficiency.

Innovation Solution

The apparatus includes a stand with a soaking tank, feeding shaft, roll shaft, stepping motor, and a scraping mechanism with an optocoupler switch for automatic initial position finding and adjustment of the scraping mechanism's angle based on input parameters, allowing quick adaptation to new films.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual debugging is used to adapt the soaking apparatus to new films, then the apparatus can be adapted to different film materials, but the debugging time is long and production efficiency is reduced

Engineering Contradiction:

Improveadaptability to different filmsVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The apparatus automatically detects film parameters (thickness, material properties) and self-adjusts soaking time, temperature, and chemical concentration without manual intervention. The system uses sensors to monitor film characteristics and automatically modifies processing parameters, enabling the apparatus to serve itself in adapting to different film types while maintaining high production efficiency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system dynamically changes processing parameters (soaking time, temperature, chemical concentration) based on detected film properties. When a new film type is introduced, the apparatus automatically adjusts these parameters to optimal values for that specific film, eliminating the need for lengthy manual debugging while maintaining adaptability

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the apparatus runs continuously for a period of time, then production efficiency is maintained, but position deviations occur requiring manual re-debugging

Engineering Contradiction:

Improveproduction efficiencyVSAvoidposition accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The apparatus incorporates position sensors and feedback mechanisms that continuously monitor the position of film feeding and soaking components. When position deviations are detected during continuous operation, the system automatically sends correction signals to actuators to realign components, maintaining position accuracy without stopping production or requiring manual intervention

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Manual mechanical adjustment mechanisms are replaced with automated electronic control systems including motors, sensors, and control algorithms. This substitution enables automatic position correction during continuous operation, maintaining reliability while preserving production efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the scraping mechanism angle is fixed, then the apparatus structure is simple, but it cannot adapt to films of different thicknesses and materials

Engineering Contradiction:

Improveapparatus structureVSAvoidadaptability to different films

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The scraping mechanism angle is made dynamically adjustable rather than fixed. The system uses motors and control systems to automatically modify the scraping angle based on detected film thickness and material properties, enabling adaptation to different films while maintaining a relatively simple overall apparatus structure through modular design

Inventive Principle:

Principle #15Dynamics

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

This solution significantly reduces debugging time and downtime, improving production efficiency by enabling quick adaptation to different films and ensuring even chemical reagent distribution on the film.

Implementation Method 1

an optocoupler switch is fixed to the stand, and assists the stepping motor to automatically find the initial position thereof

Methodology Applied

Scientific EffectOptocoupler switch light sensing: Photoelectric Effect

Implementation Method 2

The soaking method is a common film processing method. The soaking method in the prior art generally includes unfolding the film, followed by soaking it in a container containing a chemical reagent solution

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS20250196179A1Apparatus for processing film

Publication Date: 2025.06.19 LEADWAY HK

AI summary

The present invention relates to an apparatus for processing a film by a squeezing force, including a stand, a soaking tank, as well as a feeding shaft, a roll shaft, a stepping motor and a scraping mechanism mounted to the stand, respectively, wherein the rotatable pressure roll shaft presses the film to the soaking tank; the scraping mechanism includes a first scraping shaft and a second scraping shaft which are connected to the stepping motor; an optocoupler switch is fixed to the stand; the stepping motor automatically finds the initial position via the optocoupler switch; and the stepping motor automatically adjusts the position and angle of the scraping mechanism according to a parameter.