Segmented Adhesive Roller for Rapid Pattern Change
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Solution Overview
Problem
The existing adhesive application rollers require time-consuming and expensive machining to create specific adhesive patterns, which is inefficient and costly, especially when different patterns are needed for various types of materials or articles, and they are difficult to repair and maintain.
Innovation Solution
The use of plural separable discs with different adhesive patterns that can be easily swapped on a shaft to form a circumferential adhesive application surface, allowing for rapid and cost-effective application of adhesive patterns and facilitating quick repair and maintenance by replacing only damaged or dirty discs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to create adhesive patterns on rollers, then precise adhesive patterns can be achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The adhesive application roller is divided into multiple separable discs that can be independently manufactured and assembled. Each disc can be precisely machined separately and then combined to form the complete roller with the desired adhesive pattern, reducing overall manufacturing time while maintaining precision.
Solution Approach 2:
The separable discs can be reused across different roller configurations by simply changing their arrangement or combination. A single disc can serve multiple pattern requirements when combined with other discs, reducing the total number of precision-machined components needed and accelerating manufacturing.
2Manufacturing precision
If traditional machining methods are used to create adhesive patterns on rollers, then precise adhesive patterns can be achieved, but manufacturing cost increases significantly
Solution Approach 1:
By segmenting the roller into multiple discs, the cost of precision machining is distributed across smaller, more manageable components. This allows for more economical manufacturing processes on each individual disc while achieving the same overall pattern precision when assembled.
Solution Approach 2:
If a disc becomes damaged or worn, only that single disc needs to be replaced rather than the entire roller. This recovers the value of the other discs and significantly reduces long-term manufacturing and maintenance costs.
3Strength
If a single integrated roller is used, then structural integrity is maintained, but repair and maintenance become difficult and time-consuming
Solution Approach 1:
The roller is segmented into multiple discs that are joined together to form a complete structure. This segmentation maintains overall structural integrity while enabling easy repair by simply removing and replacing individual damaged discs without affecting the other components.
Solution Approach 2:
The design allows individual discs to be extracted from the roller assembly for repair or replacement. This extraction capability maintains structural integrity during operation while dramatically simplifying maintenance procedures when wear or damage occurs.
4Adaptability or versatility
If different adhesive patterns are required for different materials, then versatility is achieved, but multiple rollers must be manufactured increasing time and cost
Solution Approach 1:
The roller is segmented into multiple discs that can be arranged in different sequences or combinations to create various adhesive patterns. This allows a single roller assembly to provide multiple patterns, eliminating the need to manufacture and store multiple complete rollers for different applications.
Solution Approach 2:
The roller configuration is made dynamic and reconfigurable rather than fixed. Discs can be added, removed, or rearranged to adapt to different adhesive pattern requirements, providing versatility while reducing the time and cost associated with manufacturing multiple static rollers.
Data Source
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AI summary
An adhesive application roller (1) having a longitudinal axis of rotation (X). The roller (1) comprises plural separable discs (D1-DN) to provide a circumferential adhesive application surface (2) a first separable disc D1 having a different width and/or diameter to a second separable disc DN.