Modular Calender System for Film Testing
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Solution Overview
Problem
Existing calenders are unable to perform individual tests for developing new film products using new resin materials efficiently, requiring large devices and significant amounts of test materials.
Innovation Solution
A modular calender system with detachable and directly driveable modules, including an embossing module, trimming module, annealing module, and T-die, which can be easily reconfigured along a common rail, allowing for individual performance of multiple tests with reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional calender is used to perform multiple tests for developing new film products, then all necessary tests can be performed, but the device size becomes large and a large amount of test material is required
Solution Approach 1:
The calender is divided into multiple independently operable modules including extrusion module, rolling module, cooling module, winding module, embossing module, trimming module, and annealing module. Each module can be detached and reconfigured along a common rail, allowing the device to perform different tests with smaller effective size and reduced material requirements.
2Adaptability or versatility
If a conventional calender is used to perform multiple tests for developing new film products, then all necessary tests can be performed, but a large amount of test material is required
Solution Approach 1:
The calender is divided into multiple independently operable modules including extrusion module, rolling module, cooling module, winding module, embossing module, trimming module, and annealing module. Each module can be detached and reconfigured along a common rail, allowing the device to perform different tests with smaller effective size and reduced material requirements.
3Productivity
If modules are made detachable and reconfigurable along a common rail, then individual tests can be performed with reduced device size, but module attachment and detachment complexity increases
Solution Approach 1:
Multiple functional modules are combined along a common rail structure with standardized attachment interfaces. The rail serves as a shared support and positioning system for all modules, reducing the overall complexity of individual module connections while enabling flexible reconfiguration for different test sequences.
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 efficient and flexible testing of new film products using a small amount of test materials by allowing modular reconfiguration and reduced device size, facilitating individual performance of calendering, embossing, extrusion, and annealing tests.
Implementation Method 1
the resin film passing through the cooling rolls is cooled by a cooling medium which flows inside of the cooling rolls
Implementation Method 2
an annealing module which removes distortion of the resin film
Data Source
Figure 1
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AI summary
A calender for testing includes a two-roll module 12, a main body module 14, and a take-off module 16. The two-roll module 12 is directly and detachably fixed to an upper surface of the main body module 14, and the take-off module 16 is directly and detachably fixed to a rear side surface of the main body module 14. In addition, the calender for testing includes a base module 18, a cooling module 20, and a winder module 22. The cooling module 20 and the winder module 22 are fixed so as to move on and to be attached to and detached from an upper surface of the base module 18 along a common rail 18a.