Multi-Material Pressure Roller for Cleaning Complex Seal Flanges
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Solution Overview
Problem
Existing application devices struggle to achieve satisfactory cleaning results on complex component geometries, particularly in areas with S-bends or corners, due to inadequate compensation for angular deviations of component flanges.
Innovation Solution
The application device incorporates a pressure roller with a multi-layered structure comprising a roller base, center, and outer elements made of different materials with varying hardness and elasticity, allowing for angular deviations to be compensated through the 'springing back' effect, and a cleaning element that performs an independent rotary motion to enhance cleaning efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-material pressure roller is used for cleaning, then the structure is simple, but angular deviations of component flanges cannot be compensated resulting in unsatisfactory cleaning results
Solution Approach 1:
The pressure roller is constructed with multiple materials having different hardness values distributed in specific spatial arrangements. The first material (hardness 10-20 Shore A) provides structural support, the second material (hardness 20-40 Shore A) provides intermediate compliance, and the third material (hardness 40-60 Shore A) provides maximum compliance for compensating angular deviations. This local variation in material properties enables the roller to adapt to surface irregularities while maintaining structural integrity.
Solution Approach 2:
The pressure roller employs a composite structure combining three different elastomeric materials with progressively decreasing hardness from center to periphery. This composite construction allows the roller to simultaneously provide structural stability through the harder central material and adaptive compliance through the softer peripheral material, resolving the contradiction between structural simplicity and cleaning effectiveness on complex geometries.
2Manufacturing precision
If the cleaning element follows only the application head movement, then the system is simple, but complex geometries like S-bends and corners cannot be cleaned effectively
Solution Approach 1:
The cleaning element is given independent rotational capability through its own drive mechanism, allowing it to dynamically adapt its motion to the complex geometry of the component surface. While the application head follows a predetermined path, the cleaning element can independently rotate to maintain optimal contact with the surface, enabling effective cleaning of S-bends, corners, and other complex geometries that would be inaccessible with passive following motion only.
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 solution effectively cleans complex component geometries by compensating for angular deviations and ensuring thorough removal of contaminants, even in challenging areas like S-bends and corners, thereby improving bonding quality.
Implementation Method 1
the material of the outer roller element is advantageously significantly softer than that of the central roller element... allows angular deviations of a component flange on a receiving surface of the body component to be compensated for by the 'springing back' of the pressure roller
Implementation Method 2
a mechanical cleaning element... designed to subject the cleaning element to a rotary motion independent of the application movement of the roller head
Data Source
Figure 1
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AI summary
The present invention relates to an application device (1) for applying a sealing profile (2) to a body panel used to close a body opening, comprising a rolling head (3) for applying the sealing profile (2) to a receiving surface of the body panel and a cleaning unit (5) positioned upstream of the rolling head (3) with respect to the receiving surface of the body panel for mechanically cleaning the receiving surface, wherein the cleaning unit (5) comprises a pressure roller (6). The pressure roller (6) comprises a roller base element made of a first material, which extends over the width of the pressure roller (6). The pressure roller (6) further comprises a roller center element made of a second material, which is arranged centrally on the roller base element and has a narrower width than the roller base element.Furthermore, the pressure roller (6) comprises an outer roller element made of a third material, wherein the outer roller element is arranged surrounding the central roller element on the roller base element and on the central roller element. The third material has a lower hardness than the second material and the first material.