Mandrel Coating with Composite Resin Film for Wear Resistance
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Solution Overview
Problem
In the manufacturing process of hollow acetate tubes, mandrels tend to deteriorate due to wear, leading to apparatus stoppages and defective product formation.
Innovation Solution
A mandrel with a metal mandrel body coated with a composite resin film made from a blend of PEEK, PEKK, PPS, or PES resins with a fluorine resin, featuring bubbles within the film, is used. The composite resin film has a thickness of 50 µm to 200 µm and a surface roughness of 15 µm to 40 µm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal mandrel is used in the hollow acetate tube manufacturing process, then the mandrel provides structural strength and durability, but the mandrel surface deteriorates due to wear leading to apparatus stoppages and defective products
Solution Approach 1:
The patent applies composite materials by coating the metal mandrel surface with a composite resin film comprising PEEK resin and fluorine resin. This composite coating combines the structural strength of the metal mandrel with the wear-resistant and low-friction properties of the resin composite, preventing surface deterioration while maintaining structural integrity.
Solution Approach 2:
The patent changes the surface parameters of the mandrel by applying a resin coating that modifies surface friction, wear characteristics, and roughness. The coating transforms the metal surface into a resin-based surface with optimized tribological properties suitable for hollow acetate tube manufacturing.
2Duration of action of stationary object
If the composite resin film is made thicker to improve wear resistance, then the mandrel endurance time increases, but the manufacturing precision of the hollow acetate tube may be affected
Solution Approach 1:
The patent optimizes the film thickness parameter to a specific range (50-200 μm) that balances wear resistance with manufacturing precision. This thickness is sufficient to provide durable protection against wear while remaining thin enough to maintain the precision required for high-quality hollow acetate tube production.
3Reliability
If the mandrel surface is made smoother to reduce friction, then the mandrel durability improves, but the surface roughness needed for proper tube formation is reduced
Solution Approach 1:
The patent optimizes the surface roughness parameter to a specific range (Ra 15-40 μm) that balances durability with tube formation requirements. This controlled roughness provides sufficient friction for proper tube formation while maintaining the durability benefits of the resin coating.
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
The enhanced mandrel design significantly improves the endurance time and reduces the rejection rate of defective hollow acetate tubes, maintaining surface roughness and durability even after prolonged use.
Implementation Method 1
a composite resin film formed on the surface of the mandrel body by melting a composite resin
Data Source
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AI summary
Provided is a mandrel used in a device for manufacturing a hollow acetate tube to be used in a heating type smoking article, said mandrel comprising a metallic mandrel body and a composite resin coating film which is formed on the surface of the mandrel body by melting a composite resin comprising one or more resins selected from the group consisting of a PEEK resin, a PEKK resin, a PPS resin and a PES resin together with a fluorine resin, wherein the composite resin coating film has bubbles in the film.