Interlayer Film Roll Package with Cushioning to Suppress Creases
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Solution Overview
Problem
The vertical placement of a roll body of interlayer film on a pallet base results in an inclined state due to a gap between the winding core and the holding member, leading to contact and crease formation, which causes foaming and optical strain in laminated glass.
Innovation Solution
A roll package configuration where the pallet base has a holding member protruding on its surface, with specific geometric relationships defined by angles and distances to prevent direct contact between the pallet base and the roll body, optionally incorporating a cushioning material to support the roll body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the inner diameter of the winding core is made larger than the outer diameter of the holding member to facilitate placement, then the ease of operation is improved, but the roll body becomes inclined and contacts the pallet base causing creases
Solution Approach 1:
A cushioning material is introduced as an intermediary element between the pallet base and the roll body. This cushioning material fills the gap created by the size difference between the holding member and winding core, providing both the ease of placement (by allowing gap existence) and the vertical placement precision (by preventing direct contact and inclination). The cushioning material acts as a mediator that resolves the contradiction between operational ease and placement precision.
2Stability of the object's composition
If the roll body is placed vertically on the pallet base, then the stability is improved, but direct contact occurs causing creases and defects
Solution Approach 1:
The cushioning material is placed in advance on the pallet base before the roll body is positioned. This prior cushioning prevents direct contact between the roll body and the hard pallet base surface, thereby eliminating the harmful effect of crease generation while maintaining the stability benefits of vertical placement. The cushioning is prepared beforehand to ensure both stability and protection against defects.
3Ease of operation
If the holding member is made smaller to fit inside the winding core, then the ease of operation is improved, but the gap increases causing greater inclination
Solution Approach 1:
The cushioning material serves as a mediator that compensates for the increased gap resulting from the smaller holding member dimensions. By introducing this intermediary element, the system maintains the operational ease of inserting a smaller holding member while the cushioning material prevents the roll body from inclining, thereby preserving angular alignment precision despite the larger gap.
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
Provided is a roll package capable of suppressing generation of a crease in an interlayer film. A roll package according to the present invention includes a pallet base having a first surface, a winding core, and a roll body of interlayer film for laminated glass, wound into a roll shape on an outer peripheral face of the winding core, the pallet base has a pallet base body, and a holding member for holding the winding core, the holding member of the pallet base has a portion that protrudes upside on the first surface side of the pallet base, the winding core is held by the holding member of the pallet base, and the roll package has a specific configuration (1) or a specific configuration (2).