Slow Cure Adhesive Cellular Structure Flattening
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Solution Overview
Problem
Existing methods for manufacturing cellular window coverings result in significant material waste due to curvature issues and inefficiencies in producing wrinkle-free cellular structures, with previous technologies either scrapping a substantial portion of the material or requiring time-consuming and costly processes.
Innovation Solution
A method involving an elongated tubular structure wound on a wheel with a slow-cure adhesive applied, where a transverse cut is made before the adhesive fully cures, allowing the structure to be flattened on a flat surface, reducing curvature and enabling wider, usable cellular panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fast-cure adhesives are used to bond cellular material on a rotating arm, then production speed is improved, but the material retains curvature and cannot be used for window coverings
Solution Approach 1:
The adhesive is applied in a slow-cure formulation that allows the cellular material to be wound and positioned on a flat surface before the adhesive fully cures. This preliminary positioning on a flat surface eliminates curvature before the adhesive sets, resolving the contradiction between production speed and shape quality.
Solution Approach 2:
The adhesive's cure time parameter is changed from fast-cure to slow-cure, extending the working time window. This parameter change allows sufficient time for the material to be processed and flattened without curvature while maintaining production efficiency.
2Productivity
If material is cut from curved ends of the rotating arm, then production continuity is improved, but significant material waste occurs
Solution Approach 1:
The cellular material is preliminarily formed and flattened on a flat surface before cutting, ensuring that the entire width of the material including previously unusable curved-end material can be utilized. This eliminates the need to scrap material from curved ends while maintaining production continuity.
3Area of stationary object
If stacks are limited by arm dimensions and floor distance, then equipment footprint is reduced, but material utilization efficiency decreases
Solution Approach 1:
The adhesive cure time parameter is extended to allow material to be processed beyond the traditional stack height limitations. Material can be continuously processed and flattened on a large flat surface area, enabling full utilization of each stack without excessive scrapping while maintaining a compact equipment footprint.
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
This approach significantly reduces material waste and produces wrinkle-free cellular structures that can be cut into desired widths and lengths, enhancing production efficiency and reducing scrap rates.
Implementation Method 1
At least one longitudinal line of a slow cure adhesive is applied to the exterior surface of the elongated tubular material before that material is placed on the wheel
Implementation Method 2
any initial curvature in the stack will decrease as gravity causes the stack to flatten
Data Source
AI summary
A cellular structure is formed on a wheel from an elongated tubular structure. At least one longitudinal line of a slow cure adhesive is applied to the exterior surface of the elongated tubular material. Then the material is wrapped around a collector in a manner to cause the adhesive to be positioned between overlying surfaces of the elongated tubular material and to form a cellular structure on the collector. The cellular structure is cut from the collector before the adhesive has fully cured and is placed on a flat surface where the adhesive has fully cured.