Multi-Material Pressing Roller for Seal Flange Cleaning

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Solution Overview

Problem

Existing seal application apparatuses struggle with unsatisfactory cleaning results on complex component geometries, particularly in regions of S twists or corners, due to inability to compensate for angular deviations of component flanges.

Innovation Solution

The apparatus employs a pressing roller with a multi-material design, comprising a roller base, center, and outer elements of varying hardnesses, allowing for angular deviations to be compensated through 'rebounding', and a cleaning element that moves independently of the application process, adapting to the degree of contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical cleaning element is pressed onto the body component using a pneumatic spring mechanism, then cleaning force is applied to remove impurities, but unsatisfactory cleaning results are obtained in regions of S twists or corners due to inability to compensate for angular deviations

Engineering Contradiction:

Improvecleaning qualityVSAvoidadaptability to angular deviations

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The pressing roller is designed with a variable hardness profile along its circumference, with the outer peripheral region having a lower hardness than the inner region. This parameter change in material hardness allows the outer region to deform and adapt to angular deviations of component flanges, particularly in complex geometries like S twists and corners, while maintaining sufficient cleaning force through the softer material's ability to conform and maintain contact.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The pressing roller is constructed as a composite structure with at least two different materials: a harder inner material providing structural support and force transmission, and a softer outer material providing adaptability to surface variations. This composite design enables the roller to simultaneously maintain cleaning force and adapt to angular deviations in complex component geometries.

Inventive Principle:

Principle #40Composite materials

2Device complexity

If a single-material pressing roller is used, then the structure is simple, but it cannot simultaneously provide sufficient cleaning force and adapt to angular deviations in complex geometries

Engineering Contradiction:

Improveroller structureVSAvoidcleaning effectiveness

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the pressing roller are assigned different material properties: the inner region has higher hardness for structural integrity, while the outer peripheral region has lower hardness for adaptability. This local differentiation of material quality allows each region to perform its specific function optimally.

Inventive Principle:

Principle #3Local quality

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

This design achieves improved cleaning results on complex component geometries by effectively compensating for angular deviations and ensuring thorough removal of dust and lubricant residues, enhancing the bonding quality of seal profiles.

Implementation Method 1

compensating for angular deviations of a component flange is possible by way of the pressing roller rebounding

Methodology Applied

Scientific EffectElastic rebound: Elasticity

Implementation Method 2

at least the receiving surface of the body component must be free of dust, moisture and lubricant residues. These impurities can be removed by a cleaning unit

Methodology Applied

Scientific EffectMechanical cleaning: Friction

Data Source

PatentUS20260077437A1Seal application apparatus with pressing roller comprising multiple elements

Publication Date: 2026.03.19 THYSSENKRUPP AUTOMOTIVE BODY SOLUTIONS GMBH

AI summary

An application apparatus for applying a seal profile to a body component serving to close a body opening comprises a roll-on head for applying the seal profile to a receiving surface of the body component and a cleaning unit intended for mechanical cleaning of the receiving surface and positioned at the front of the roll-on head with respect to the receiving surface of the body component, wherein the cleaning unit comprises a pressing roller. The pressing roller comprises a roller base element made of a first material extending over the width of the pressing roller. The pressing roller further comprises a roller center element made of a second material arranged centrally on the roller base element and having a smaller width than the roller base element. In addition, the pressing roller comprises a roller outer element made of a third material, wherein the roller outer element is arranged on the roller base element so as to surround the roller center element and is arranged on the roller center element. The third material has a lower hardness than the second material and the first material.