Heatable Roller with Central Axial Heating Module

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Solution Overview

Problem

The production of heated laminating rollers often results in high scrap rates due to imperfect cylindrical surfaces, leading to difficulties in applying a roller cover and inefficiencies in heat transfer, which increases costs and reduces the effectiveness of the lamination process.

Innovation Solution

A heatable roller design featuring a cylindrical roller tube with a central axial pass-through opening for a rod-shaped heating module, allowing for a seamless and torque-proof connection, and an elastic roller cover that can be easily applied, ensuring a consistent and efficient heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a roller body is assembled from multiple components, then the structural complexity is reduced, but the manufacturing precision deteriorates due to imperfect cylindrical surfaces and edges

Engineering Contradiction:

Improveroller body structureVSAvoidcylindrical surface quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The roller body is designed as a single integrated component rather than an assembly of multiple parts. This merging of components eliminates the edges and protrusions that occur at junctions between separate parts, thereby achieving a perfectly cylindrical outer surface without requiring complex assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a roller cover is applied to an assembled roller body, then the functionality is improved, but the ease of manufacture deteriorates due to wedging at edges and protrusions

Engineering Contradiction:

Improveroller cover applicationVSAvoidroller cover installation

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By integrating the roller body as a single component without edges or protrusions, the roller cover can be applied smoothly without wedging issues. The seamless cylindrical surface allows for straightforward installation of the roller cover, improving ease of manufacture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The roller body is pre-formed as a complete single-component structure with a perfectly cylindrical surface before the roller cover is installed. This preliminary preparation of the roller body ensures that the subsequent roller cover application is simple and free from defects caused by edges or protrusions.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If injection molding is used to apply a roller cover, then the productivity is improved, but the manufacturing precision deteriorates due to scrap rates of up to 17%

Engineering Contradiction:

Improveroller production speedVSAvoidroller cover thickness consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The integration of the roller body as a single component eliminates the need for complex roller cover application processes. This reduces the scrap rate associated with injection molding operations while maintaining high productivity, as fewer parts need to be reworked or discarded due to thickness inconsistencies.

Inventive Principle:

Principle #5Merging (Combining)

4Use of energy by moving object

If a PTC heating rod is used, then the use of energy is improved through self-regulation, but the device complexity increases due to external control requirements

Engineering Contradiction:

Improveheating power regulationVSAvoidcontrol system

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The PTC heating rod automatically regulates its own heating power based on temperature changes without requiring external control systems. The material's inherent positive temperature coefficient property causes the heating rod to reduce its power output as temperature increases, providing self-regulation that eliminates complex control electronics while maintaining energy efficiency.

Inventive Principle:

Principle #25Self-service

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 design significantly reduces scrap rates during production, enhances heat transfer efficiency, and allows for lower operating temperatures, reducing energy consumption and enabling a more compact housing, while maintaining effective lamination performance.

Implementation Method 1

rod shaped heating module which is arranged in a central axial pass through opening of the roller body

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

ensuring a consistent and efficient heat transfer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

elastic roller cover which is supported at an outer surface of the roller body

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10479062B2Heatable roller for laminators and laminator with the heatable roller

Publication Date: 2019.11.19 MONOLITH GMBH

AI summary

A heatable roller, in particular a laminating roller for laminators, the heatable roller including a roller body including a cylindrical outer surface and defining a longitudinal axis; an elastic roller cover which is supported at the outer surface of the roller body; and a rod shaped heating module which is arranged in a central axial pass through opening of the roller body and which is connected at least torque proof with the roller body, characterized in that the roller body includes a cylindrical roller tube which defines a central axial pass through opening in which the rod shaped heating module is arranged.