Laminate Manufacturing Needle Stabilization with Non-Contact Guides

Solution Overview

Problem

Conventional devices for manufacturing layered materials with elastic threads face limitations in speed due to periodic tension fluctuations causing belt and needle vibration, leading to potential damage and reduced operational efficiency.

Innovation Solution

Employing a non-contact type stabilizer, such as an air or magnetic guide, to stabilize the reciprocating needle and belt movement, preventing friction and allowing for higher operational speeds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If mechanical guide members (linear guides) are used to prevent vibration, then stability is improved, but device complexity and friction increase, limiting operating speed

Engineering Contradiction:

Improvestability of needle and belt movementVSAvoidcomplexity of guide mechanism

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent replaces mechanical guide members (linear guides) with a non-contact magnetic guide system. The magnetic guide uses magnetic fields to guide and stabilize the reciprocating motion of the needle and belt without physical contact, thereby eliminating mechanical friction and wear while maintaining stability. This substitution resolves the contradiction by improving stability without increasing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a non-contact guide mechanism using magnetic fields (analogous to pneumatic/hydraulic principles of using fluid or field media instead of solid contact). The magnetic guide creates a non-contact environment that allows the reciprocating components to move smoothly without mechanical friction, thereby enabling higher operating speeds while maintaining stability.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If mechanical guide members are used to prevent vibration, then reliability is improved, but friction increases causing wear and limiting speed

Engineering Contradiction:

Improvereliability of reciprocating mechanismVSAvoidfriction and wear

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical guide members (linear guides) with a non-contact magnetic guide system. The magnetic guide uses magnetic fields to guide and stabilize the reciprocating motion of the needle and belt without physical contact, thereby eliminating mechanical friction and wear while maintaining stability. This substitution resolves the contradiction by improving stability without increasing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a non-contact guide mechanism using magnetic fields (analogous to pneumatic/hydraulic principles of using fluid or field media instead of solid contact). The magnetic guide creates a non-contact environment that allows the reciprocating components to move smoothly without mechanical friction, thereby enabling higher operating speeds while maintaining stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables higher-speed operation without wear, enhancing productivity by stabilizing the reciprocating motion of the needle and belt, thus improving the manufacturing process efficiency.

Implementation Method 1

the guide 4 is an air guide or a magnetic guide

Methodology Applied

Scientific EffectAir blowing:

Implementation Method 2

the guide 4 is an air guide or a magnetic guide

Methodology Applied

Scientific EffectMagnetic force: Magnetic Field

Data Source

PatentEP4249233B1Apparatus and method for manufacturing laminate

Publication Date: 2025.08.13 ZUIKO CORP

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AI summary

The present invention provides a device for manufacturing a layered material including an elastic thread sandwiched between a pair of sheets, including: a pair of nip rolls arranged with their axes parallel to each other for nipping the elastic thread between the pair of sheets being conveyed in a conveyance direction; a needle arranged upstream of the nip roll in the conveyance direction for guiding and arranging the elastic thread between the pair of sheets while dispensing the elastic thread through a through hole, through which the elastic thread passes; a needle body 11 that holds the needle 1; a reciprocating section, to which the needle body is attached, for reciprocating in a width direction, which intersects with the conveyance direction; and a stabilizer that stabilizes the reciprocation of the reciprocating section, wherein the stabilizer is a non-contact-type guide.