Friction-Wheel Buffer Forming for Low-Deformation Honeycomb Cores
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Solution Overview
Problem
Conventional honeycomb paper buffers face issues with high manufacturing costs, uneven surfaces, and reduced buffering effectiveness due to compression and bending during shaping, leading to increased shipping costs and inefficiencies in production.
Innovation Solution
A buffer forming machine that continuously presses and conveys a honeycomb core through a feed, shaping, and rebound stages using friction wheels to maintain minimal deformation and ensure a smooth, fast production process, forming hexagonal honeycomb bodies with controlled expansion and rebounding to maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional honeycomb paper buffers are compressed and bent during shaping to form folds, then the buffer structure is formed, but the buffering effectiveness is reduced and surface unevenness occurs
Solution Approach 1:
The invention divides the buffer into a honeycomb core portion and separate folded portions (wings). The honeycomb core maintains its original cushioning structure without compression or bending, while the folded portions are separately formed and attached to provide the necessary structural shape and folding functionality.
Solution Approach 2:
The invention extracts the folding function from the honeycomb core structure itself and relocates it to separate folded portions (wings) that are attached to the core. This allows the core to retain its optimal cushioning geometry while the wings provide the necessary folds and structural form.
2Volume of moving object
If honeycomb paper buffers are made with expanded structure to increase buffering volume, then the buffering capacity is improved, but the manufacturing cost increases
Solution Approach 1:
The invention pre-forms the honeycomb core to the desired expanded volume and shape before attachment of the folded portions. This preliminary formation of the core structure eliminates the need for costly post-expansion processes and ensures consistent buffering volume without increasing manufacturing complexity.
3Stability of the object's composition
If folded portions are secured to honeycomb core by bonding to maintain structure, then the structural integrity is improved, but the shipping cost increases due to expansion space
Solution Approach 1:
The invention uses thin folded portions (wings) that can be flat-packed against the honeycomb core during shipping. These flexible folded portions provide structural integrity when attached but occupy minimal space during transport, significantly reducing shipping costs compared to fully expanded buffer structures.
4Reliability
If honeycomb paper buffers are continuously formed without compression to maintain buffering effectiveness, then the buffering effectiveness is maintained, but the shaping difficulty increases
Solution Approach 1:
The invention segments the buffer formation process into two independent stages: (1) forming the honeycomb core without compression to maintain buffering effectiveness, and (2) separately forming and attaching the folded portions to provide structural shape. This segmentation eliminates the conflict between maintaining core integrity and achieving desired buffer shape.
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 machine effectively forms buffers with maintained buffering effectiveness and reduced deformation, ensuring a stable and efficient manufacturing process while minimizing material compression and surface unevenness.
Implementation Method 1
A buffer forming machine that continuously presses and conveys a honeycomb core through a feed, shaping, and rebound stages using friction wheels
Implementation Method 2
forming hexagonal honeycomb bodies with controlled expansion and rebounding to maintain structural integrity
Data Source
AI summary
A buffer forming machine includes a frame and a roller unit. The roller unit includes at least two friction wheel sets spaced apart from each other, one of the at least two friction wheel sets defining a feed region, another one of the at least two friction wheel sets defining an output region. A ratio of a height of the output region in the height direction to a height of the feed region in the height direction is greater than 70%. The height of the feed region in the height direction is configured to be 90-95% of a height of each of the plurality of sheet materials in the height direction. The height of the output region in the height direction is configured to be 70-75% of the height of each of the plurality of the sheet materials.