Winding Device Precompression Roller Friction Reduction
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Solution Overview
Problem
Existing winding devices for fibrous mats suffer from high friction forces during the rolling process, which can damage the mats and degrade their insulating properties, especially at higher speeds and when using high compression ratios.
Innovation Solution
A winding device with a precompression belt system featuring a movable compression roller and guide surfaces forming an acute angle, where the precompression surface is a rolling element with a curved downstream end and additional rollers, reducing friction and ensuring uniform pressure for controlled compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a precompression plate is used to compress the mat to the desired compression rate, then the compression ratio is improved, but the friction force increases and damages the mat
Solution Approach 1:
The patent replaces the sliding precompression plate with a rolling precompression roller. This substitution changes the mechanical interaction from sliding friction to rolling friction, dramatically reducing the friction force applied to the mat while maintaining the necessary compression rate. The roller rotates in contact with the mat, creating a rolling motion that minimizes surface damage and fiber degradation.
Solution Approach 2:
The invention changes the physical state and motion parameters of the precompression element. Instead of a stationary or linearly moving plate, a rotating roller is used, which introduces rotational motion and changes the contact dynamics. This parameter change transforms the harmful sliding friction into beneficial rolling friction, allowing effective compression without mat damage.
2Productivity
If the running speed of the mattress is increased to improve productivity, then the production rate is improved, but the friction force increases and degrades the mattress quality
Solution Approach 1:
The rolling roller system allows the mat to be processed at higher speeds without proportionally increasing friction damage. The rolling contact mechanism naturally accommodates higher velocities while maintaining lower friction coefficients compared to sliding contact, enabling increased productivity without sacrificing mat quality.
3Quantity of substance
If a precompression plate is used to achieve high compression ratio, then the bulk reduction is improved, but the thickness recovery quality deteriorates
Solution Approach 1:
The rolling action of the precompression roller applies compression forces more uniformly and gently compared to a sliding plate. This rolling compression reduces fiber breakage and binder degradation, allowing the mat to maintain its structural integrity and thickness recovery capabilities even at high compression ratios.
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 minimizes friction and maintains the integrity of the fibrous mats by distributing compressive stress uniformly, preserving their thickness recovery and insulating qualities even at high speeds and high compression ratios.
Implementation Method 1
the precompression surface is a rolling element, since it is formed by the strip of the precompression mat stretched and running against the downstream assembly. Consequently, compared to the case where the pressure force is exerted on the mattress by a sliding element, the friction at the interface between the mattress and the precompression surface is greatly reduced
Data Source
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AI summary
This winding device for the formation of fibrous rolls comprises: - a first conveyor belt (3) and a second conveyor belt (4), - a movable compression roll (52) which delimits, together with guiding surfaces (37, 47) of the conveyor belts (3, 4), a winding zone (10), - a movable precompression belt (7) having an upstream roll, and a downstream assembly (74, 75, 76) having a curved downstream end (76) and a strip (71) which is wound around the upstream roll and the downstream assembly (74, 75, 76). The strip (71) held taut against the downstream assembly (74, 75, 76) forms, opposite the guiding surface (37) of the first conveyor belt (3), a moving precompression surface (79) of a fibrous mat to be wound, this precompression surface (79) being the precompression element closest to the winding zone (10).