Nested Roller Core Member for Shrink Film Storage
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Solution Overview
Problem
Current core members for heat shrink film rolls are inefficient in holding large amounts of film with fewer splices and require longer times to wind and unwind, leading to increased costs and logistical challenges during transportation and use.
Innovation Solution
A core member comprising a plurality of concentric rollers, including an inner, intermediate, and outer roller, with a gear system that allows for efficient winding and unwinding, reducing the need for splices and enhancing film capacity by up to 250% per pallet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single core member is used to hold film, then the structure is simple, but the film capacity is limited and requires more splices
Solution Approach 1:
The core member comprises multiple rollers nested within each other (inner roller, intermediate roller, outer roller). When expanded, these rollers provide multiple surfaces for winding film, significantly increasing film capacity. When collapsed, they nest within each other to minimize space for transportation. This nesting principle allows the core member to hold up to 250% more film per pallet while maintaining transport efficiency.
Solution Approach 2:
The core member is divided into multiple functional rollers instead of a single structure. Each roller can independently wind film, and the segmented design allows the film to be wound in sections across different rollers, reducing the need for splices and allowing continuous film operation.
2Productivity
If film is wound onto a single core member, then the winding process is simple, but the winding time is long
Solution Approach 1:
The winding process is segmented across multiple rollers operating simultaneously. While one roller is being wound, another can be prepared or is already in use. This parallel processing through segmentation reduces total winding time significantly compared to a single roller system.
Solution Approach 2:
The multiple rollers allow continuous winding action without interruption. As film is wound on one roller, another roller is ready to receive the film, eliminating idle time and maintaining continuous productive action throughout the winding process.
3Productivity
If multiple splices are made to wind film onto multiple core members, then the film can be distributed, but the process time increases
Solution Approach 1:
Multiple rollers are merged into a single core member assembly, allowing multiple film winding operations to occur simultaneously on one unit. This combines the functionality of multiple separate core members into one, eliminating the need for multiple splices and distribution operations while maintaining high productivity.
Solution Approach 2:
The segmented roller design enables continuous film feeding across multiple winding surfaces without interruption for splicing. The film can be continuously wound from one roller to another, maintaining uninterrupted useful action and eliminating time-consuming splice operations.
Data Source
AI summary
A core member is provided for storing shrink film. The core member includes a plurality of rollers, each having a disc and a core extending upwardly from the disc. The plurality of rollers are aligned longitudinally along an axis and laterally along a plane. The plurality of rollers are rotatable to wind the shrink film about the rollers.