Rotating Cutting and Suction Wheel for Substrate Handling
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Solution Overview
Problem
Current methods lack an industrial process for producing aerosol substrates with low dimensional variations without manual intervention, particularly for thin substrates like those with a flat plate shape.
Innovation Solution
A method involving a continuous web of substrate material being cut by a rotating cutting wheel with multiple dies and conveyed, followed by lifting using a suction wheel with circumferentially arranged suction areas, allowing for serial formation and collection of substrates with constant shape and weight without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual cutting methods are used to produce substrates, then dimensional variations can be controlled, but productivity is low and manual labor is required
Solution Approach 1:
The continuous web cutting process is segmented into multiple cutting dies arranged circumferentially on a rotating cutting wheel, allowing simultaneous cutting of multiple substrates in parallel while maintaining consistent dimensions through precise mechanical positioning of each cutting die
Solution Approach 2:
Manual cutting operations are replaced by an automated rotating cutting wheel mechanism that mechanically cuts substrates from the continuous web at high speed, eliminating manual labor while maintaining dimensional consistency through precision engineering of the cutting dies and their positioning
2Productivity
If automated cutting processes are used, then productivity increases, but manufacturing precision deteriorates due to lack of control
Solution Approach 1:
The cutting dies are pre-positioned on the rotating cutting wheel at precise intervals and angles before operation begins, ensuring that each substrate is cut at the correct position and orientation, thereby maintaining dimensional consistency throughout high-speed automated production
Solution Approach 2:
The system uses multiple cutting dies simultaneously acting on the continuous web, providing redundant cutting capability that ensures consistent dimensional results even at high production speeds where individual cutting variations might occur
3Device complexity
If substrates are conveyed without lifting mechanism, then device complexity is reduced, but collection and handling becomes difficult
Solution Approach 1:
The suction wheel introduces a vertical lifting dimension to the otherwise planar conveyor system, lifting substrates from the horizontal conveyor surface into a collection zone above, thereby facilitating easy collection and handling without significantly complicating the overall device architecture
4Measurement precision
If manual substrate handling is used, then substrate positioning is accurate, but loss of time increases due to manual intervention
Solution Approach 1:
The suction wheel automatically performs the substrate lifting and positioning function that would otherwise require manual handling, creating a self-service mechanism that maintains positioning accuracy through controlled suction and release while eliminating the time loss associated with manual intervention
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 industrial generation and collection of substrates with consistent shape and weight, reducing manual labor and potential cost, and allowing for reduced dimensions in aerosol generation devices.
Implementation Method 1
the lifting step may be carried out by means of a suction wheel comprising suction areas each configured to generate a reduced pressure to suction a defined substrate on the conveyor
Data Source
AI summary
A method allows for serially forming a plurality of substrates for aerosol generation, and includes the steps of:feeding (110) a continuous web of substrate material,cutting out (120) the continuous web to define a plurality of substrates by rotating a cutting wheel having multiple cutting dies arranged circumferentially,conveying (130) the defined substrates by a conveyor, andlifting (140) the defined substrates from the conveyor by rotating a suction wheel having multiple suction areas arranged circumferentially.