Variable-Speed Corrugation Rollers for Adjustable Flute Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional corrugation processes are limited by inflexible frequency and amplitude adjustments, high costs due to expensive rollers, difficulty in processing larger amplitudes, and inability to handle materials with low plasticity, 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 drive substrates with a middle substrate at varying velocities, forming flutes anchored between them, allowing for adjustable corrugation patterns, adaptable to different materials, and enhanced water resistance, while reducing the need for expensive equipment and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional corrugating rollers are used to mold the medium into waveform, then the medium can be corrugated, but the frequency and amplitude of the wave are not easily adjustable and require roller swapping which causes downtime
Solution Approach 1:
The patent applies dynamics by making the corrugation profile adjustable during operation. Instead of fixed rollers, the system uses a form roller with a variable profile that can be dynamically adjusted to change the frequency and amplitude of the corrugation waveform without requiring physical roller replacement, thereby eliminating changeover downtime.
Solution Approach 2:
The patent implements parameter changes by allowing the form roller profile to be modified to alter the corrugation characteristics. The roller profile parameters (frequency, amplitude, wavelength) can be changed while the equipment is running, enabling flexible adjustment of the output waveform without stopping production for roller swaps.
2Adaptability or versatility
If expensive sets of rollers are used for corrugation, then various frequencies and amplitudes can be achieved, but the cost increases significantly
Solution Approach 1:
The patent applies universality by designing a single form roller that can perform multiple functions - producing various frequencies and amplitudes of corrugation waves through profile adjustment. This eliminates the need for multiple specialized rollers, reducing equipment cost while maintaining versatility.
Solution Approach 2:
The patent uses copying by creating a variable profile on the form roller that can replicate different corrugation patterns. Instead of owning multiple physical rollers for different patterns, the system uses one roller whose profile can be copied or adjusted to match desired waveforms, reducing the number of expensive physical components needed.
3Shape
If conventional corrugating rollers are used, then smaller corrugations (1/8th to 1/4 inch amplitude) can be produced, but larger corrugations (1 inch to several feet) become cost prohibitive
Solution Approach 1:
The patent applies dynamics by using a form roller with a variable profile that can be adjusted to produce different amplitude corrugations. This allows the system to economically produce both small and large amplitude corrugations without requiring prohibitively expensive oversized rollers, as the profile can be dynamically adapted to the desired amplitude.
4Strength
If materials with low plasticity such as rubber or certain plastics are used, then water resistance and strength are improved, but the materials are difficult to corrugate using conventional methods
Solution Approach 1:
The patent applies preliminary action by preparing the material surface or structure before corrugation. The system may apply adhesives, coatings, or pre-treatments to materials with low plasticity to improve their corrugatability, allowing rubber and certain plastics to be successfully corrugated without compromising their inherent strength and water resistance properties.
Data Source
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.