Surface Winder Leading Edge Device for Adhesive-Free Core Attachment
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Solution Overview
Problem
Current surface winders face issues with misalignment and mis-attachment of web material to the core due to adhesive application, leading to mal-formed products and process shut-downs, as the adhesive can deposit on equipment surfaces, causing operational disruptions.
Innovation Solution
A surface winder design with a leading edge device featuring a pressure-sensitive valve and textured surface to apply adhesive directly to the core during the winding process, ensuring accurate attachment and eliminating the need for external adhesive application, thereby reducing slippage and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied to the core before insertion into the winding cradle, then the web material can be attached to the core, but the adhesive may misalign or mis-attach the web material, causing mal-formed products and process shut-downs
Solution Approach 1:
The adhesive is applied to the core in advance by the adhesive applicator before the core is inserted into the winding cradle. This preliminary action ensures that the adhesive is already positioned on the core surface, allowing the web material to be attached accurately as it enters the winding zone, thereby improving both reliability and manufacturing precision.
Solution Approach 2:
The adhesive acts as an intermediary substance between the core and the web material. By applying the adhesive to the core surface, it mediates the attachment process, ensuring proper bonding while maintaining alignment accuracy. The adhesive applicator precisely controls where the adhesive is placed, preventing misalignment issues.
2Reliability
If adhesive is applied to the core externally before winding, then the web material can be attached, but the adhesive deposits on equipment surfaces causing operational disruptions
Solution Approach 1:
The adhesive applicator applies adhesive only to the specific local area of the core surface where the web material will contact. This localized application ensures that adhesive is present only where needed for attachment, preventing excess adhesive from depositing on surrounding equipment surfaces and causing operational disruptions.
Solution Approach 2:
The adhesive applicator is integrated into the core insertion mechanism, allowing the core to receive adhesive application automatically as part of its own preparation process. This self-service approach ensures adhesive is applied precisely where needed without requiring separate external application steps that could lead to equipment contamination.
3Object-generated harmful factors
If the core is inserted into the winding cradle without adhesive, then equipment remains clean, but the web material cannot be attached to the core
Solution Approach 1:
The adhesive is applied to the core in advance by the adhesive applicator before the core is inserted into the winding cradle. This preliminary action ensures that the adhesive is already positioned on the core surface, allowing the web material to be attached accurately as it enters the winding zone, thereby improving both reliability and manufacturing precision.
Solution Approach 2:
The adhesive acts as an intermediary substance between the core and the web material. By applying the adhesive to the core surface, it mediates the attachment process, ensuring proper bonding while maintaining alignment accuracy. The adhesive applicator precisely controls where the adhesive is placed, preventing misalignment issues.
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 improves the accuracy of web material attachment, reduces mal-formed products, and prevents adhesive deposition on equipment, enhancing manufacturing efficiency and reducing process interruptions.
Implementation Method 1
A surface winder design with a leading edge device featuring a pressure-sensitive valve and textured surface to apply adhesive directly to the core during the winding process
Implementation Method 2
A surface winder design with a leading edge device featuring a pressure-sensitive valve and textured surface to apply adhesive directly to the core during the winding process, reducing slippage and misalignment
Data Source
AI summary
A surface winder for winding a web material around a core to obtain a log is disclosed. The surface winder provides a core inserter for inserting a core into an introductory portion of a winding cradle defined by an upper winding roller, a concave cradle, a lower winding roller, and a third oscillating roller. The concave cradle has a leading edge device having a surface with at least one channel disposed therein. The at least one channel has a single entry point and a single exit point and extending from a position external to the leading edge device and a first location disposed upon the surface capable of receiving a fluid from the at least one channel. The fluid is fluidically displaced onto the core from the at least one channel when the core is in contacting engagement with the first location disposed upon the surface.