Clamshell Lamination System for Hydraulic Press Replacement

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Solution Overview

Problem

Existing high-speed lamination processes require large, expensive, and heavy hydraulic presses for lid management and clamping, limiting access and mobility, and suffer from high thermal energy waste and safety concerns due to their size and thermal mass.

Innovation Solution

A high-speed lamination machine with a hinged, clamshell lid and pneumatically actuated rollers that eliminates the need for hydraulic presses, allowing for localized heating and easy access, and incorporates stepper motors for precise pin positioning and automated systems for improved thermal management and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a hydraulic press is used for lid management and clamping in high-speed lamination processes, then the required clamping force and lid management capability are achieved, but the system becomes extremely heavy and expensive

Engineering Contradiction:

Improveclamping forceVSAvoidsystem weight

Core Design Contradiction:

ForceVSWeight of stationary object

Solution Approach 1:

The patent extracts and removes the hydraulic press from the lamination system, replacing it with a clamshell-style lid mechanism that uses mechanical leverage and counterweights to achieve the required clamping force without the heavy hydraulic infrastructure

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the hydraulic mechanical system with a purely mechanical lever-based system using the clamshell lid, which uses rotational mechanics and counterbalancing to generate clamping force without hydraulic fluid pressure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Force

If a hydraulic press is positioned directly above the chamber for lid management, then the clamping force is effectively applied, but access to the interior of the chamber is limited

Engineering Contradiction:

Improveclamping forceVSAvoidchamber access

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The patent inverts the traditional top-down clamping approach by using a clamshell lid that opens laterally or rotates outward, allowing access from the side or front of the chamber while still applying vertical clamping force when closed

Inventive Principle:

Principle #13The other way round (Inversion)

3Temperature

If the entire press frame is heated throughout the day to maintain temperature, then thermal uniformity is achieved, but thermal energy waste is high

Engineering Contradiction:

Improvethermal uniformityVSAvoidthermal energy waste

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent implements localized heating zones within the chamber rather than heating the entire press frame, using targeted heating elements only where thermal energy is needed for the lamination process, thereby reducing overall energy consumption while maintaining thermal uniformity in the work area

Inventive Principle:

Principle #3Local quality

4Productivity

If high frequency use of the hydraulic pump system occurs, then productivity is maintained, but the entire system becomes hot and may take hours to cool down

Engineering Contradiction:

Improveoperation frequencyVSAvoidsystem temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent replaces the hydraulic pump system with a mechanical lever system that does not generate heat through fluid compression, allowing for high-frequency operation without thermal accumulation in the actuation mechanism

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces system weight and size, enabling easier repositioning and access, while minimizing thermal waste and enhancing thermal uniformity and safety, allowing for efficient high-duty-cycle operation without overheating.

Implementation Method 1

uses localized and thermally isolated heating

Methodology Applied

Scientific EffectLocalized heating: Heating

Implementation Method 2

a hinged, clamshell lid, and clamped lamination chamber

Methodology Applied

Scientific EffectMechanical advantage: Mechanical Advantage

Data Source

PatentEP3785912B1Clam shell lamination system

Publication Date: 2022.10.26 ROCKWELL COLLINS INC

Figure 1A
Figure 1B
Figure 1C

AI summary

A high-speed lamination machine (100) includes a hinged, clamshell lid (104), and clamped lamination chamber (102) that uses localized and thermally isolated heating and stepper driven separation pin motion. Pneumatically actuated rollers (200) in a track (202) clamp the lamination chamber (102) closed during operation. The clamshell design obviates the need for a hydraulic press and makes the lamination chamber (102) easily accessible to other automated systems, so robots may be used to place lamination elements within the chamber (102).