Uniformly Rough Winding Core Tube for Wrinkle-Free Foil Winding
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Solution Overview
Problem
Copper and aluminum foil tends to wrinkle and slip during winding due to its soft and smooth nature, leading to inefficiencies and waste in the winding process.
Innovation Solution
A winding core tube with a uniformly rough surface is designed, featuring a rotary barrel with sprayed particles of varying diameters (2-15 μm) and a reinforcement agent, which increases friction and prevents slippage, allowing for smoother winding and reduced wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a smooth winding core tube is used, then the copper and aluminum foil can be easily wound, but the foil is prone to generate wrinkles and bubbles and is not easy to wind tightly
Solution Approach 1:
The surface roughness parameter of the winding core tube is changed from smooth to uniformly rough through sandblasting treatment. This parameter change increases the friction between the core tube and the foil, enabling tight winding without wrinkles or bubbles, while maintaining ease of operation through the uniform distribution of the rough surface.
2Device complexity
If a smooth winding core tube is used, then the winding process is simple, but slippage occurs during transportation causing foil to fall off
Solution Approach 1:
The surface friction parameter is changed by applying a rough coating layer on the core tube. This increases the friction force between the core tube and the wound foil, preventing slippage during transportation and improving reliability, while the core tube structure itself remains simple and unchanged.
3Reliability
If a rough surface is applied to the winding core tube, then friction is increased to prevent slippage, but the surface becomes non-uniform causing wrinkles
Solution Approach 1:
The surface treatment parameters are optimized by controlling the sandblasting process to achieve a uniform roughness distribution. This maintains high friction stability for preventing slippage while ensuring the rough surface is uniformly distributed to avoid causing wrinkles or bubbles during winding.
Solution Approach 2:
The rough surface treatment is applied uniformly across the entire core tube surface rather than locally. This ensures consistent friction characteristics throughout the winding area, preventing both slippage and localized defects like wrinkles, while maintaining overall surface uniformity.
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 enables stable and efficient winding of copper and aluminum foil, reducing the risk of wrinkles and slippage, improving transportation stability and reducing waste by ensuring a uniform thickness and tighter roll formation.
Implementation Method 1
sprayed particles are sprayed on the outer side of the rotary barrel... copper and aluminum foil is sleeved on the outer side of the rotary barrel... increases friction and prevents slippage
Data Source
AI summary
A winding core tube with a uniformly rough surface including a rotary barrel is provided. A circular through hole is provided at the inner side of the rotary barrel, a rotating sleeve is fixedly connected at the circular through hole of the rotary barrel, a circular through hole is provided at the outer side of the rotating sleeve, a connecting shaft is fixedly connected at the circular through hole of the rotating sleeve, the length of the connecting shaft is larger than that of the rotary barrel, and sprayed particles are sprayed on the outer side of the rotary barrel.