Rubber Sheet Meandering Supply for Uniform Bank Formation
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Solution Overview
Problem
Existing rubber sheet manufacturing methods using calendering struggle to maintain uniform rubber pool formation along the axial direction of calender rolls, leading to uneven rubber sheet thickness and reduced productivity due to non-uniform supply of continuous rubber material.
Innovation Solution
An apparatus and method involving a rubber supply device that supplies continuous rubber material in a meandering state onto a conveyor, with full width and partial width moving modes to ensure uniform bank formation by adjusting the oscillation width and direction, allowing for the return of edge portion rubbers to the bank, thereby maintaining uniformity along the calender rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a continuous rubber material is supplied from a direction perpendicular to the axial direction of calender rolls using a reciprocating guide member, then the rubber material can be supplied over the whole length of the calender rolls, but the amount of bank becomes non-uniform in the axial direction of the calender rolls
Solution Approach 1:
The guide member is made movable in the axial direction of the calender rolls, transitioning from a static to a dynamic supply system. The guide member reciprocates along the axial direction to distribute rubber material uniformly across the entire length of the calender rolls, ensuring both complete coverage and uniform bank formation through controlled dynamic motion.
2Productivity
If ear portion rubbers cut from both edge portions are returned to banks at both axial end portions of calender rolls, then productivity is improved by reusing material, but the amount of bank at end portions becomes larger than at the center portion
Solution Approach 1:
The supply system provides different quantities of rubber material to different axial positions of the calender rolls. The guide member is positioned to supply more rubber material to the end portions where ear rubbers are returned, and less to the center portion, creating a non-uniform supply pattern that compensates for the localized accumulation and maintains uniform bank formation throughout.
3Area of stationary object
If the guide member moves in a reciprocating manner to supply rubber material over the whole length of calender rolls, then the coverage is improved, but the continuous rubber material is pulled toward the large rubber pool and cannot be supplied uniformly to other end portions
Solution Approach 1:
The guide member is positioned and moved in advance to control the flow of rubber material before it accumulates into uneven pools. By reciprocating the guide member along the axial direction, the system proactively distributes material to prevent localized accumulation, ensuring consistent supply to all portions of the calender rolls before imbalances can develop.
Data Source
AI summary
In one embodiment of an apparatus for manufacturing a rubber sheet, a continuous rubber material is supplied onto a supply conveyor in a meandering state by supplying the continuous rubber material onto the supply conveyor while moving rubber supply device in a reciprocating manner in a roll axial direction. The rubber supply device has a full width moving mode in which the rubber supply device moves in the roll axial direction such that the continuous rubber material has a meandering shape of a width corresponding to a width of a rubber sheet, and a partial width moving mode in which the rubber supply device moves in the roll axial direction such that the continuous rubber material has a meandering shape of a width obtained by excluding widths of both edge portions of the rubber sheet from the width of the rubber sheet.