Energy-Absorbing Winding Core Structure for Controlled Collapse
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Solution Overview
Problem
Conventional winding cores collapse abruptly and are insufficient in absorbing roll strain energy, leading to excessive inside diameter reduction and vibration issues, especially when handling materials wound under high tension.
Innovation Solution
A winding core design featuring a cylindrical structure with a radially inner shell, an outer shell, and an energy-absorbing zone formed by collapsible layers with three-dimensional structured atomic regions that absorb and distribute pressure, allowing controlled collapse over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional corrugated paperboard layers are used in winding cores, then the core can immediately relieve some radially inward compression, but the core collapses too abruptly and causes high vibration during rotation
Solution Approach 1:
The patent changes the geometric parameters of the collapsible structure by using polyhedral cells with specific face configurations (e.g., octagonal prisms, hexagonal prisms) instead of conventional corrugated layers. This structural parameter change allows the core to collapse in a more controlled, progressive manner rather than abruptly, reducing vibration while maintaining compression relief capability
Solution Approach 2:
The patent creates a dynamic collapse behavior where the polyhedral cellular structure progressively collapses under radial load through controlled buckling of its faces and edges. This dynamic response allows the core to adapt to varying compression forces over time, providing sustained compression relief without sudden collapse that would cause vibration
2Loss of energy
If prior-art radially compressible regions are used, then some roll strain energy can be absorbed, but the structure does not have sufficient capacity to absorb large pressure from high-tension winding
Solution Approach 1:
The patent employs composite construction by combining polyhedral cellular structures with core wall materials (such as paperboard or plastic) to create a composite core structure. This composite approach integrates the energy-absorbing characteristics of the cellular geometry with the structural strength of the core material, enabling sufficient capacity to absorb large pressures from high-tension winding while maintaining overall structural integrity
Solution Approach 2:
The patent utilizes a porous-like polyhedral cellular structure within the core wall that provides void spaces for energy absorption. This cellular geometry creates a controlled porous structure that can compress and collapse to absorb roll strain energy, while the surrounding core material maintains structural strength to handle high-tension winding pressures
3Manufacturing precision
If the core wall is made stronger to resist compression, then ID comedown is reduced, but the core cannot adequately absorb roll strain energy from high-tension winding
Solution Approach 1:
The patent applies local quality by creating zones of different structural properties within the core wall. The polyhedral cellular regions provide localized energy absorption capacity where needed, while other portions of the core wall maintain higher strength to preserve inside diameter stability. This spatial variation in structural quality allows the core to simultaneously manage compression and absorb energy
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 design significantly reduces inside diameter reduction and length growth, improving core stability and material efficiency by effectively managing roll strain energy and maintaining core integrity under prolonged pressure.
Implementation Method 1
the roll of wound material stores energy referred to herein as 'roll strain energy' because of the tension under which the film is wound around the core and/or because of the shrinkage of the material after winding
Implementation Method 2
the compressive load from the roll also causes the core to grow in length
Data Source
AI summary
Winding cores for elastically stretched or shrinkable materials are designed to significantly reduce the amount of roll strain energy developed during winding. This is accomplished by building into the core an energy-absorbing zone (220) that can be collapsed by a substantial amount and in a relatively controlled fashion over a substantial period of time under the influence of a continued radially inward pressure exerted by the roll of wound material. The energy-absorbing zone is formed by one or more collapsible layers (100) having repeated atomic regions (105) projecting out of a plane of the sheet and each defining a plurality of normal vectors (108a, 108b, 108c, 108d) in different sub-regions of the atomic region, wherein the normal vectors, when projected onto the two-dimensional plane of the sheet, are in a plurality of different directions in the plane.