Woven Fabric Roller with Segmented Weave Patterns for Dust Control
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Solution Overview
Problem
Conventional rollers used in conveyor apparatuses face issues such as dust adhesion, fraying, and increased manufacturing costs due to the limitations of existing cover materials, which affect conveyance characteristics and require frequent maintenance.
Innovation Solution
A roller with a surface covering made of woven fabric featuring varying weave patterns and yarn densities to create lattice-like holes and non-gap forming portions, preventing fraying and dislocation while allowing for adjustable friction and air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If solid rubber rollers with high coefficient of friction are employed to convey sheet-like objects, then conveyance characteristics are improved, but paper dust and fibrous waste adhere to the roller surface causing degradation of conveyance characteristics
Solution Approach 1:
The roller surface is segmented into multiple circumferential bands with different weave patterns. Gap-forming portions create regions with lower friction coefficient while non-gap-forming portions maintain higher friction. This segmentation allows the roller to convey sheet-like objects effectively while reducing dust adhesion in specific zones.
Solution Approach 2:
Different portions of the roller surface are given different local qualities through varied weave patterns. The gap-forming portions have a more open structure with lower friction, while non-gap-forming portions have a denser structure with higher friction. This local differentiation optimizes both conveyance and dust prevention in respective zones.
2Object-generated harmful factors
If rollers covered with fluorocarbon resin tubes are used to prevent dust adhesion, then dust adhesion is reduced, but friction coefficient becomes too low for effective conveyance
Solution Approach 1:
The roller surface is divided into multiple circumferential bands where gap-forming portions provide low friction for dust prevention and non-gap-forming portions provide high friction for conveyance. This segmentation allows simultaneous achievement of both low dust adhesion and effective conveyance in different zones.
Solution Approach 2:
Different local qualities are implemented through varied weave patterns. Gap-forming portions have open structures with lower friction coefficients suitable for dust prevention, while non-gap-forming portions have denser structures with higher friction coefficients for effective sheet conveyance.
3Ease of manufacture
If conventional woven fabric coverings are used on rollers, then manufacturing cost is reduced, but the fabric frays and dislocates during rotation affecting reliability
Solution Approach 1:
The woven fabric is segmented into repeating units of gap-forming and non-gap-forming portions. This structured segmentation creates a self-stabilizing pattern that resists fraying and dislocation during rotation while maintaining cost-effectiveness through standard weaving techniques.
Solution Approach 2:
Instead of trying to prevent fraying through additional coatings or treatments, the invention inverts the approach by designing the weave pattern itself to inherently resist fraying. The alternating gap and non-gap portions create structural stability that prevents edge fraying and dislocation without additional protective layers.
4Object-generated harmful factors
If suction holes are formed on roller surface for cooling or suction, then air permeability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The roller surface is segmented into gap-forming portions that naturally provide air permeability through the woven fabric structure itself, eliminating the need for additional suction holes. This segmentation achieves air permeability through the weave pattern rather than through drilled or molded openings.
Solution Approach 2:
The gap-forming portions of the woven fabric act as porous structures, allowing air to pass through the fabric weave itself. This natural porosity provides cooling and suction functions without requiring additional holes or openings, simplifying manufacturing while maintaining air permeability.
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 woven fabric covering enhances the roller's durability, reduces maintenance needs, and allows for customizable friction levels, improving conveyance efficiency and reducing manufacturing costs while preventing fraying and dislocation.
Implementation Method 1
rollers which are cylindrical bodies having a multiplicity of slits formed therein and which are formed such that fibril-like material is wound thereabout have been developed, these being used as rollers in apparatuses for manufacture of resin film and/or sheet
Implementation Method 2
a roller for which friction at a surface thereof is required
Data Source
Figure 1(a)~2(b)
Figure 3(a)~4(b)
Figure 5(a)~6(b)
AI summary
To provide a roller which has woven fabric at a surface thereof and which is employed in an apparatus permitting achievement of conservation of resources, conservation of energy, and low cost, and an apparatus employing such a roller. Roller 1 provided with covering 3 comprising woven fabric at a surface thereof is idler means or drive means for conveying, supply, or the like of an object, means for air cooling or drying a moving object, rotating means making use of suction of an object, or is for cleaning a contact surface to which roller 1 is opposed, and has at the surface thereof woven fabric 2 comprising variation or combination of weave pattern(s); said woven fabric 2 has a step comprising weaving in a linear pattern of bands or different patterns; has open holes comprising lattice-like gaps 8 or a rectangular pattern 6 for control of air permeability formed from weft yarn 25 and warp yarn 26; and is a roller 1 having woven fabric 2 at the surface thereof which is constituted from a non-gap-forming portion 7 in a rectangular pattern 6 due to mutual approach or abutment of yarns 5 of woven fabric 2 and rectangular gap-forming portion 9.