Adhesive Sheet Joining with Synchronized Separator Folding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current adhesive sheet joining methods face issues with restricted separation speed of release paper, leading to incomplete separation and uneven adhesion, resulting in lower tension and potential rupture, as well as transfer of surface unevenness from the sheet supporting part to the adhesive sheet, causing wavy surfaces during heat treatment.
Innovation Solution
An adhesive sheet joining method and apparatus that utilize a transporting mechanism with a separator larger than the adhesive sheet, where the separator is held and folded back by a holder moving in a direction crossing the transportation direction, allowing for synchronized separation and uniform tension application, ensuring complete separation and uniform adhesion without surface unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressurizing roller firmly holds the release paper to separate it from the resin sheet, then the release paper separation is achieved, but the separation speed is restricted leading to lower tension and potential rupture
Solution Approach 1:
The pressurizing roller is designed to swing downward dynamically during the separation process, allowing the system to adapt the pressing force and separation speed in real-time. This dynamic movement enables complete separation while maintaining sufficient tension to prevent rupture, resolving the contradiction between separation completeness and separation speed.
2Ease of manufacture
If the sheet supporting part has serrated unevenness to prevent adhesion, then the adhesive sheet can be placed without sticking, but the unevenness is transferred to the adhesive face causing wavy surface after heat treatment
Solution Approach 1:
A release film is introduced as an intermediary layer between the sheet supporting part and the adhesive sheet. This release film prevents adhesion during the placement process while maintaining a smooth surface that does not transfer unevenness to the adhesive sheet, thereby preventing wavy surface defects after heat treatment.
Solution Approach 2:
The mechanical serrated unevenness system is replaced with a chemical/release-based system using the release film. Instead of relying on physical surface features to prevent adhesion, the invention uses the release properties of the film to achieve non-adhesive placement while preserving surface quality.
3Reliability
If the release paper is larger than the adhesive sheet, then the release paper can be held and separated effectively, but the protruding release paper causes tension concentration leading to rupture
Solution Approach 1:
The pressurizing roller swings downward dynamically during separation, distributing the separation force progressively across the release paper. This dynamic action prevents sudden tension concentration at the protruding edges, maintaining release paper integrity while achieving complete separation.
Solution Approach 2:
The system is designed to control the separation process in advance, ensuring that the release paper is separated gradually and uniformly. The pressurizing roller's controlled movement provides cushioning against sudden tension spikes that would cause rupture, while still achieving complete separation.
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
Enables high-speed, accurate joining of adhesive sheets to steel plates with uniform thickness and tension, reducing cycle time and preventing adhesion issues, while ensuring complete separation without rupture or surface defects.
Implementation Method 1
separating the separator from the adhesive sheet by holding a portion of the separator protruding from a front end of the adhesive sheet with a holder on a tip of an arm of a separating mechanism in front of the adhesive sheet in a standby state, and by moving the holder in a direction crossing a transportation direction of the adhesive sheet
Implementation Method 2
moving the transporting mechanism in synchronization with movement of the holder in the transportation direction while folding back the separator at an end of a supporting member contacting the separator as a starting point
Implementation Method 3
joining an adhesive sheet to a steel plate of transport machinery including automobiles and various types of industrial machinery for reinforcement or vibration suppression
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
While a transporting unit 5 transports an adhesive sheet S attached to a separator 3 larger than the adhesive sheet S, a chuck member 34 on a tip of a swing arm 33 of a separating unit 6 holds a portion of the separator 3 protruding from an end of the adhesive sheet. Under such a condition, the chuck member 34 moves in a direction crossing a transportation direction of the adhesive sheet, and the transporting unit 5 moves in the transportation direction in synchronization with the chuck member 34 while folding back the separator 3 at an end of a supporting plate 9 contacting the separator 3 as a starting point. Accordingly, the separator 3 is separated from the adhesive sheet S. The transporting unit 5 transports while holding the adhesive sheet S with the separator 3 separated therefrom to join the adhesive sheet S to a workpiece W.