Surface Winder Core Support with Internal Pressurization
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Solution Overview
Problem
Surface rewinding machines face challenges in maintaining structural stability and strength of convolutely wound rolls due to low basis weight and high caliper web materials, leading to radial deformation and instability during the winding process.
Innovation Solution
A rewinding machine design that incorporates a core support system with rotatable pins providing positive pressure to the core, enhancing its stability and structural strength by increasing the inherent bend modulus, thus preventing radial deformation and ensuring a stable winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If low basis weight and high caliper web materials are used, then manufacturing costs are reduced and material usage is decreased, but the structural stability and strength of the core/web material system deteriorates, leading to radial deformation and instability during winding
Solution Approach 1:
The patent applies parameter changes by modifying the physical state of the core through internal pressurization. By introducing pressurization means (pneumatic or hydraulic systems) that apply internal pressure to the core, the core's structural parameters are dynamically altered during the winding process. This increases the core's bend modulus and structural stability without changing the web material properties, thereby resolving the contradiction between using less material and maintaining structural stability.
2Ease of manufacture
If low basis weight web material is used, then production costs are decreased, but the bend modulus of the core/web material system is reduced, causing radial deformation during winding
Solution Approach 1:
The patent changes the physical parameter of the core by applying internal pressure through pneumatic or hydraulic means. This pressurization increases the core's stiffness and bend modulus dynamically during winding, compensating for the inherently lower bend modulus of low basis weight web materials without increasing material costs.
Solution Approach 2:
The patent applies preliminary action by pressurizing the core before and during the winding process. The pressurization system is activated in advance to ensure the core achieves sufficient structural strength before the web material is wound around it, preventing radial deformation from occurring in the first place rather than correcting it afterward.
3Quantity of substance
If high caliper web material is used, then material coverage is improved, but the core/web material system becomes unstable during winding
Solution Approach 1:
The patent addresses the stability issue by changing the physical state of the core through internal pressurization. The pressurization system dynamically adjusts core stiffness to match the winding process requirements, ensuring stable winding of high caliper materials without compromising the material coverage benefits.
4Device complexity
If conventional core support is used, then device complexity is minimized, but the core experiences radial deformation and instability
Solution Approach 1:
The patent introduces pneumatic or hydraulic pressurization systems to provide internal pressure to the core. This allows for dynamic control of core structural properties without requiring complex mechanical reinforcement structures. The pneumatic/hydraulic system provides a simple yet effective means of stabilizing the core while maintaining relatively low device complexity.
Solution Approach 2:
The patent replaces traditional mechanical core support structures with a pressurization-based system. Instead of using complex mechanical fixtures, guides, or support frameworks to stabilize the core, the invention uses internal pressure fields (pneumatic or hydraulic) to achieve the same stabilizing effect with a different physical mechanism.
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 effectively increases the stability and structural strength of the core and the core/web material system, resulting in a consumer-acceptable convolutely wound product that meets manufacturing and financial targets, even with low basis weight and high caliper web materials.
Implementation Method 1
The source of positive pressure provides a positive pressure to the interior portion of the core through the channel from the first end of the first rotatable pin to the second end of the first rotatable pin
Data Source
AI summary
A rewinding machine for convolutley winding a web material onto a core to is disclosed. The rewinding machine comprises a first winding drum rotatable at a first peripheral velocity, a second winding drum opposed to the first winding drum and rotatable at a second peripheral velocity, and a core support for gripping opposing ends of the core. The core support grips opposing ends of the core during winding of the web material about the core. The core support has first and second rotatable pins each having corresponding first and second ends capable of insertion into a respective end of the core. The first rotatable pin has a channel that provides fluid communication between a source of positive pressure disposed external to the first rotatable pin and the second end of the first rotatable pin to provide positive pressure to the interior portion of the core.