Iris Rolling Assembly for Compact Web Material Rolls
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Solution Overview
Problem
Existing methods for packaging web materials in rolls often result in loosely rolled or larger diameter rolls, and the use of shafts or spindles adds material costs and weight, creating waste and inefficiencies.
Innovation Solution
A rolling assembly with a base member, intermediate members, and a top member forming an iris mechanism that adjusts its cross dimension to tightly package web material into a roll, using movable components and adjustable pressure to control the roll's diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shaft or spindle is used to form a roll, then the roll structure is stable and easy to manufacture, but material costs increase, weight increases, and waste increases
Solution Approach 1:
The patent removes the shaft or spindle from the roll formation system entirely. Instead of using a central support element, the invention uses the web material itself to form the roll structure through a self-contained mechanism where the material is folded and secured without external support, thereby eliminating the waste and cost associated with shafts or spindles
Solution Approach 2:
The web material serves its own purpose of forming the roll structure. The material is folded back on itself and secured through the mechanism, making the system self-sufficient without requiring external support elements like shafts or spindles. The material both forms the roll and provides its own structural support
2Loss of substance
If web material is rolled without a shaft or spindle, then material costs and weight are reduced, but the roll becomes loosely rolled with larger diameter
Solution Approach 1:
The patent employs a dynamic mechanism where the web material is continuously folded and secured as it is fed through the system. The material is folded back on itself in a controlled manner and secured through a mechanism that maintains consistent roll tightness throughout the process, allowing the roll to form dynamically with precise control over its dimensions and compactness
3Loss of substance
If web material is rolled without a shaft or spindle, then material costs and weight are reduced, but the roll diameter becomes larger than desired
Solution Approach 1:
The patent employs a dynamic mechanism where the web material is continuously folded and secured as it is fed through the system. The material is folded back on itself in a controlled manner and secured through a mechanism that maintains consistent roll tightness throughout the process, allowing the roll to form dynamically with precise control over its dimensions and compactness
Data Source
AI summary
Rolling assembly for packaging web material in a roll having a base member with concave arcuate feed surface defining an upwardly-extending ramp, first intermediate member movably coupled to base member, and top member moveably coupled to at least one of base member or first intermediate member, top member having a concave arcuate pressure surface facing feed surface of base member. The base member, first intermediate member and top member collectively forming an iris with a feed space, the iris moveable between a first condition and a second condition, and configured to receive web material along the feed surface and direct the web material upwardly toward the top member to form a roll within the feed space, the iris moving toward a second condition as the roll of web material increases in cross dimension against the pressure surface of the top member.