Apparatus and method for making a corrugated product
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Solution Overview
Problem
Conventional corrugation processes are limited by inflexible frequency and amplitude adjustments, high costs due to expensive roller sets, difficulty in processing larger amplitudes, and inability to handle materials with low plasticity or high memory, such as rubber or certain plastics, which lack the necessary support and water resistance.
Innovation Solution
A method and apparatus that uses upper and lower drive rollers to propel a middle substrate at a higher velocity than the upper and lower substrates, forming flutes anchored between them, allowing for adjustable corrugation patterns, reduced material costs, and the ability to process a variety of substrates, including those with low plasticity, while providing improved strength and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional corrugation processes use fixed roller sets to determine wave frequency and amplitude, then manufacturing precision is maintained, but adaptability deteriorates because frequency and amplitude cannot be easily adjusted
Solution Approach 1:
The patent applies dynamics by making the corrugation system adjustable through variable frequency drivers that control the rotational speeds of rollers. This allows the wave frequency and amplitude to be dynamically changed during operation by adjusting motor speeds, rather than requiring physical roller changes. The system maintains precision through controlled variable speed operation while achieving adaptability through electronic speed control.
Solution Approach 2:
The patent changes physical parameters by varying the rotational speeds of the rollers through variable frequency drives. By changing the speed parameters of the rollers, the system can produce different wave frequencies and amplitudes without changing the roller geometry itself. This allows continuous adjustment of corrugation parameters while maintaining manufacturing precision through controlled parameter variation.
2Manufacturing precision
If expensive roller sets are used to achieve precise corrugation, then manufacturing precision is maintained, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a single roller system that can perform multiple corrugation functions through variable speed control. Instead of requiring different roller sets for different wave patterns, one universal roller system with adjustable speeds can produce various frequencies and amplitudes. This reduces device complexity and cost while maintaining manufacturing precision through electronic control.
Solution Approach 2:
The patent substitutes mechanical complexity with electronic control by replacing the need for multiple physical roller sets with a single roller system controlled by variable frequency drives. The mechanical system is simplified to one roller set, while the control system becomes electronic/software-based, allowing precise adjustment of corrugation parameters without complex mechanical changes.
3Productivity
If conventional corrugation processes use slow substrate feeding, then manufacturing precision is maintained, but productivity deteriorates
Solution Approach 1:
The patent applies dynamics by implementing variable speed control for both substrate feeding and roller rotation. The system can dynamically adjust speeds to optimize the ratio between feeding rate and roller speed, ensuring precise flute formation even at high production speeds. This allows productivity to increase while maintaining manufacturing precision through coordinated variable speed operation.
4Productivity
If conventional corrugation processes use multiple roller sets for different amplitudes, then manufacturing precision is maintained, but loss of time increases due to roller changes
Solution Approach 1:
The patent eliminates downtime for roller changes by implementing dynamic speed control. Instead of stopping production to change rollers, the system continuously operates a single roller set at variable speeds to produce different amplitudes and frequencies. This maintains manufacturing precision while eliminating time loss associated with mechanical roller changes.
Solution Approach 2:
The patent replaces the mechanical roller change system with an electronic speed control system. Instead of physically changing rollers to adjust amplitude and frequency, the system uses variable frequency drives to electronically control roller speeds, allowing continuous production without mechanical intervention or downtime.
Data Source
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AI summary
The invention describes a device and method for making corrugated products. The device can be used with any substrate and includes, at least, first and second drive rollers for driving a middle substrate and a single wall corrugated product. In other embodiments the invention includes upper drive rollers, lower drive rollers and middle drive rollers for driving an upper substrate, a lower substrate and a middle substrate. The middle substrate is driven between the upper and lower substrates at a higher velocity to form flutes that are anchored between the upper an lower substrates thereby forming a corrugated product. The invention also provides for customized corrugated products having multiple fluted substrates in various desirable arrangements. Examples of such products include mattress, partition panels, other furniture and construction products.