Split Rubber Roll Structure for Fast Partial Replacement
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Solution Overview
Problem
Conventional rubber rolls face issues with lengthy replacement processes due to entire roll separation, non-uniform wear, increased weight, and vibration, leading to reduced productivity and waste generation.
Innovation Solution
A partially replaceable rubber roll design comprising split rolls and rubber covers, with integrated fastening and reinforcing features, allowing for easy assembly and disassembly, reduced weight, and balanced weight distribution, preventing eccentricity and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire rubber roll is replaced when worn, then the rubber layer is renewed, but the replacement process is lengthy and reduces productivity
Solution Approach 1:
The rubber roll is divided into multiple independent rubber layers that can be replaced separately. Each rubber layer is attached to a cylindrical surface and can be detached and replaced without removing the entire roll, enabling quick maintenance while maintaining high productivity.
2Strength
If the rubber roll is made thick to ensure durability, then strength is improved, but weight increases and causes sagging
Solution Approach 1:
The rubber roll structure is segmented into multiple thin rubber layers instead of one thick layer. This segmentation maintains the required durability and strength while reducing the overall weight, preventing sagging and non-uniform wear caused by excessive weight.
3Strength
If fastening bolts are used to secure rubber layers, then bonding strength is improved, but weight balance is adversely affected causing eccentricity
Solution Approach 1:
The fastening bolts are extracted from the design and replaced with adhesive bonding. The rubber layers are secured to the cylindrical surface using adhesive, which maintains bonding strength without introducing heavy metal fasteners that would disrupt weight balance and cause eccentricity.
4Ease of manufacture
If the rubber roll is designed as a single piece, then manufacturing is simple, but replacement requires entire roll separation
Solution Approach 1:
The rubber roll is designed as multiple separable rubber layers attached to a cylindrical surface. This segmentation maintains manufacturing simplicity while enabling easy replacement of individual worn layers without removing the entire roll, significantly improving ease of repair.
Data Source
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AI summary
The present invention provides a partially replaceable rubber roll capable of significantly improving productivity through mass production of split rolls, reducing weight by thinning, enhancing bonding strength with a rubber layer, maintaining weight balance, and preventing eccentricity or vibration. The partially replaceable rubber roll comprises a core forming a rotation shaft, a plurality of split rolls, each formed in a semi-cylindrical shape so as to cover the core in an upper and lower divided manner, the split rolls being formed in a short length so as to cover an entire length of the core in multiple sections, and a plurality of rubber covers respectively surrounding outer circumferential surfaces of the split rolls and integrally combined and fixed thereto. Each of the split rolls comprises a semi-cylindrical body and flanges formed to protrude outward by a predetermined width along opposite longitudinal edges of the body, wherein each flange is formed with a pair of fastening holes spaced apart in a longitudinal direction and configured to allow penetration and fastening by fastening members.