Motorized Roller Cavity Filling with Vinyl Resin Bag

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Solution Overview

Problem

Conventional motorized rollers face issues with dew condensation and noise due to large cavities, which lead to component breakdown and low workability when filling urethane foam fillers, as they deform and create frictional forces during insertion.

Innovation Solution

A method involving a bag made of vinyl resin to accommodate an elastic body, which is compressed to fit inside the roller body without friction, then expanded to fill the cavity, reducing dew condensation and noise while improving workability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If urethane foam filler is pressed into the roller body cavity, then the cavity is filled to prevent dew condensation and reduce noise, but the filler deforms at the ends and creates frictional forces that reduce workability

Engineering Contradiction:

Improvedew condensation preventionVSAvoidworkability of filler insertion

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses a flexible bag made of vinyl resin to encapsulate the elastic body filler. This flexible shell allows the filler to be inserted in a compressed state without direct contact between the filler and roller body inner surface, eliminating frictional forces. The bag maintains its flexibility while providing a smooth interface that prevents deformation at the ends of the roller body.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The vinyl resin bag acts as an intermediary between the elastic body filler and the roller body cavity. By introducing this intermediate layer, the patent eliminates direct frictional contact and allows easy insertion and removal of the filler. The bag serves as a mediator that transfers the filling function while avoiding the harmful frictional effects of direct contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the roller body cavity is large to accommodate motor components, then the motor can be housed, but substantial water builds up dew condensation in the cavity causing breakdown and rusting

Engineering Contradiction:

Improvemotor accommodationVSAvoiddew condensation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical parameters of the filler by using an elastic body with high resilience instead of conventional urethane foam. This elastic body is inserted in a compressed state (changed volume parameter) and then expands to fill the cavity, providing effective dew condensation prevention while accommodating the motor components in the remaining space.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies preliminary action by pre-compressing the elastic body filler before insertion into the roller body cavity. The filler is compressed to a smaller volume, inserted into the cavity along with the bag, and then allowed to expand automatically to fill the space. This preliminary compression enables easier insertion while ensuring complete cavity filling for dew condensation prevention.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the roller body cavity is large, then motor components can be accommodated, but the cavity increases reverberation caused by collision between articles and the roller

Engineering Contradiction:

Improvecomponent accommodationVSAvoidnoise

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the acoustic parameters by introducing an elastic body filler with high resilience and damping properties. This material effectively absorbs collision impacts and reduces reverberation within the cavity, thereby reducing noise generation while allowing the cavity to maintain its size for component accommodation.

Inventive Principle:

Principle #35Parameter changes

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 method effectively prevents dew condensation from reaching motor components, reduces noise, and enhances the longevity and workability of motorized rollers by using a compressible and resilient filler that expands within the roller body.

Implementation Method 1

Removal of air from the bag accommodating the elastic body compresses the elastic body

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

taking air in the bag so as to expand the elastic body so that the cavity is filled with the bag accommodating the elastic body

Methodology Applied

Scientific EffectExpansion: Elastic Recovery

Implementation Method 3

the bag is expected to be made of vinyl resin, which will generate smaller friction force than urethane foam

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS7846081B2Method for producing motorized roller and motorized roller produced by the method

Publication Date: 2010.12.07 ITOH ELECTRIC COMPANY LIMITED

AI summary

A method for producing a motorized roller formed by accommodating a motor in a roller body so that the roller body is rotated when being driven by the motor, including the steps of: providing at least one elastic body; providing a bag for accommodating the elastic body; inserting the elastic body into the bag; removing air from the bag; inserting the bag accommodating the elastic body into a cavity of the roller body; and taking air in the bag so as to expand the elastic body so that the cavity is filled with the bag accommodating the elastic body.