Honeycomb Foundation Roller With Capillary Cooling Channels
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Solution Overview
Problem
Existing methods for producing honeycomb-patterned foundation sheets for beehives are complex, require multiple steps, and are not cost-effective for small beekeepers who lack sufficient wax quantities, often necessitating the use of externally sourced wax that may introduce diseases or pesticide residues.
Innovation Solution
A device with counter-rotating rollers featuring chambers and capillary-connected channels for separating and cooling agents, allowing for direct application of beeswax without additional processing steps, and enabling production through additive manufacturing for simplicity and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-step production methods are used for foundation sheets, then the honeycomb pattern can be produced, but the production process becomes complex and requires multiple processing steps including casting, imprinting, trimming, and cutting
Solution Approach 1:
The patent combines multiple production steps (casting, imprinting, trimming, cutting) into a single integrated roller device. The roller simultaneously performs pattern imprinting and edge trimming in one operation, eliminating the need for separate processing steps and reducing overall production complexity while maintaining pattern quality
Solution Approach 2:
The roller is designed with multi-functional capabilities: it serves as both an imprinting tool for creating the honeycomb pattern and a trimming tool for cutting the foundation sheet edges. The hollow cylindrical structure with internal chambers allows it to also function as a cooling device, making a single component perform multiple tasks that previously required separate devices
2Quantity of substance
If small beekeepers use externally sourced wax for foundation sheet production, then sufficient material quantity is available, but the risk of introducing diseases, pests, or pesticide residues increases
Solution Approach 1:
The invention enables small beekeepers to produce their own foundation sheets using their own collected wax, making the production process self-sufficient. The simplified single-step roller device allows them to process small quantities of wax without needing to source material externally, thereby eliminating contamination risks while maintaining adequate material supply for their needs
3Ease of manufacture
If wax is used without cooling agents during production, then the production process is simple, but the wax deforms and adheres to the roller
Solution Approach 1:
The patent introduces cooling agents (such as water or alcohol) as intermediaries between the hot wax and the roller surface. These agents are supplied through channels in the hollow roller to the outer circumferential surface, where they cool the wax immediately upon contact, preventing deformation and adhesion while maintaining production simplicity
Solution Approach 2:
The invention replaces complex mechanical cooling systems with a simpler fluid-based cooling approach. Instead of using mechanical refrigeration or complex thermal management systems, the hollow roller delivers cooling agents directly to the wax through internal channels, achieving effective cooling with minimal mechanical complexity
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
Facilitates the production of honeycomb-patterned foundation sheets from beeswax with reduced risk of contamination and deformation, enhancing dimensional stability and reducing production effort, making it feasible for small beekeepers to produce high-quality sheets efficiently.
Implementation Method 1
at least one connecting channel (6), which connects the chamber (K) to the projecting end (5E) of at least one of the honeycomb-shaped projections (5)
Implementation Method 2
it improves the cooling of the roller and the core material, thereby accelerating curing and consequently enhancing the core's dimensional stability
Implementation Method 3
The addition of a separating agent and/or coolant reduces the risk of the core material adhering to the roller, thus preventing damage and minimizing deformation of the core
Data Source
Figure 1a~1b
Figure 2~3
AI summary
In order to provide a device (1) which is constructed as simply as possible, can be produced as cost effectively as possible and allows foundations (M) for beehives to be produced as simply as possible from the bees' own wax with as few work steps as possible, at least one roller (3) is provided in the device (1), on the outer circumferential surface (U) of which roller (3) a plurality of honeycomb-shaped projections (5) are provided for forming the honeycomb pattern on the foundation (M), wherein each honeycomb-shaped projection (5) comprises, on the side thereof facing away from the outer circumferential surface (U) of the roller (3), a free projection end (5E), wherein at least one chamber (K) for receiving a release agent and/or coolant is provided within the roller (3), and at least one connection channel (6) is provided on the roller (3), which connection channel (6) connects the chamber (K) to the free projection end (5E) of at least one of the honeycomb-shaped projections (5) and/or to the outer circumferential surface (U) of the roller (3).