Offset Roller Compression for Dust-Reduced Composite Cutting
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Solution Overview
Problem
Existing portable cutting machines for composite materials fail to effectively delaminate and cut various types and thicknesses, producing harmful dust and solid particles, and lack efficient dust reduction and recycling systems.
Innovation Solution
A portable machine with a compression module featuring offset rollers and a diamond wire cutting system, accompanied by a water recycling and dust decanting system, to facilitate delamination, cutting, and reduce environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If symmetrically arranged rollers are used for compression, then the structure is simple, but the fibres cannot be fractured and delamination does not occur
Solution Approach 1:
The patent applies asymmetry by arranging rollers in a staggered configuration where top rollers are vertically offset from bottom rollers by an angle of 45°±15°. This asymmetric arrangement creates effective delamination by fracturing fibres, whereas symmetric arrangements fail to achieve proper delamination despite structural simplicity.
2Device complexity
If conventional cutting methods are used, then the cutting process is simple, but all types and thicknesses of composite materials cannot be cut effectively
Solution Approach 1:
The patent implements universality through a diamond wire cutting system that can effectively cut all types and thicknesses of composite materials. The diamond wire, combined with the preliminary delamination from offset rollers, creates a universal cutting solution that adapts to various material properties and dimensions, unlike conventional cutting methods with limited applicability.
3Device complexity
If compression is applied without fibre fracturing, then the compression process is simple, but subsequent cutting is significantly limited
Solution Approach 1:
The patent applies preliminary action by using offset rollers to fracture fibres and create delamination before the cutting operation. This preliminary delamination action, achieved through asymmetric roller compression, significantly enhances subsequent cutting efficiency and enables the processing of thick composite pieces that would otherwise be difficult to cut.
4Device complexity
If cutting is performed without dust control, then the process is simple, but harmful dust and solid particles are produced
Solution Approach 1:
The patent converts the harmful dust generation into a beneficial water recycling and dust decanting system. Water is used during cutting to suppress dust, then collected and recycled through a decanting system that separates solid particles from water, transforming the harmful dust problem into a controlled water-based dust suppression and recycling process.
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 effective cutting of composite materials of any type and thickness, minimizing dust emission and optimizing transport by recycling water and reducing CO2 emissions.
Implementation Method 1
a cutting module (7) arranged after the compression module (2), wherein the cutting module (7) comprises a cutting element (7) configured to cut the piece of composite material
Implementation Method 2
a water recycling and dust decanting system
Data Source
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AI summary
The invention relates to a portable machine (1) for cutting pieces of composite material, comprising a compression module (2) which comprises one or more top rollers (4) and two or more bottom rollers (6), wherein the top rollers (4) are coupled to a mechanism configured to vertically move said top rollers (4), thereby compressing the pieces to be cut, wherein at least one top roller (4) is vertically offset with respect to a bottom roller (6) adjacent to the same, the offset angle (α) being comprised between 45° ± 15°, in such a way that the piece of composite material is compressed by the rollers (4, 6) in a direction that is substantially perpendicular to the direction of the fibres, fracturing, delaminating and breaking the same before the cut is made in a diamond wire cutting module (7).