Coating Device Deflector Pressure Energy Source
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Solution Overview
Problem
Existing surface finishing methods for plate-shaped workpieces in the furniture industry face challenges such as large equipment dimensions due to cooling requirements, adhesive blocking issues, energy inefficiency, and quality drawbacks from low adhesive quantities, particularly with conventional adhesives like EVA, which remain adhesive at room temperature.
Innovation Solution
A device and method for coating workpieces using a deflector and pressure means with an integrated energy source to activate the adhesive on the material web, allowing for precise temperature and pressure control, enabling efficient application and handling of material webs with reduced adhesive quantities and avoiding blocking, while allowing for both inline and offline coating methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional adhesives like EVA are used with reduced quantities, then adhesive activation is improved, but blocking occurs due to residual adhesiveness at room temperature
Solution Approach 1:
The patent changes the temperature parameter of the adhesive from room temperature to elevated temperature (above 50°C) to alter its adhesive properties. At elevated temperatures, the adhesive maintains sufficient bonding capability while preventing residual adhesiveness that causes blocking. This parameter change allows reduced adhesive quantities to be used effectively without causing blocking issues.
Solution Approach 2:
The adhesive is pre-heated to activation temperature before application to the material web. This preliminary heating ensures the adhesive is in its activated state during handling and application, preventing blocking while maintaining bonding effectiveness. The adhesive is then cooled only immediately before contact with the workpiece surface.
2Reliability
If material webs are cooled to below reaction temperature for storage, then blocking is prevented, but equipment dimensions become very large due to cooling lines
Solution Approach 1:
Instead of pre-cooling the adhesive and maintaining it at low temperatures through extended cooling lines, the invention applies cooling only immediately before the adhesive contacts the workpiece surface. This eliminates the need for large-volume cooling lines and storage systems, reducing equipment dimensions while still preventing blocking.
Solution Approach 2:
The invention extracts the cooling function from a continuous, system-wide requirement and applies it only at the specific moment and location where it is needed - immediately before adhesive contact with the workpiece. This removes the need for extensive cooling infrastructure.
3Ease of operation
If material webs are guided through deflecting rollers at low temperatures, then handling is possible, but adhesive film damage occurs due to residual adhesiveness
Solution Approach 1:
The invention maintains the adhesive at elevated temperatures (above 50°C) during handling and guiding operations, changing its physical state from sticky at room temperature to non-sticky at elevated temperature. This allows the material web to be guided through deflecting rollers and handling equipment without the adhesive film sticking to surfaces or being damaged.
4Reliability
If hot-melt adhesive is applied in hot state and then cooled down, then blocking is prevented, but energy consumption becomes very high due to large heat input and subsequent cooling
Solution Approach 1:
The adhesive is heated to activation temperature once and maintained at this temperature throughout the handling, guiding, and application process. Cooling is applied only immediately before contact with the workpiece surface, eliminating the need for continuous cooling that would consume significant energy. This preliminary heating approach reduces overall energy consumption while still preventing blocking.
Solution Approach 2:
The adhesive remains in its activated hot state continuously during all handling and application operations, maintaining its non-sticky properties throughout the process. This continuous maintained state eliminates the need for repeated heating and cooling cycles, reducing energy consumption while ensuring blocking prevention.
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 enables convenient handling and application of material webs with reduced energy input, compact device design, and improved production speed, while maintaining adhesive activation until application, thus addressing energy and environmental concerns and quality issues.
Implementation Method 1
at least an energy source whose point of action is located in the area of the pressure means, in particular in an area of the pressure means, which is at least in sections in contact with the material web. Through the point of action energy is provided into the material web.
Implementation Method 2
a pressure means for applying the material web onto the surface of the workpiece
Implementation Method 3
When the material web with the activated adhesive is subsequently applied onto the workpiece surface by means of the pressure means, the material web can be glued to the workpiece and thus be fixed on the workpiece
Data Source
AI summary
The present invention provides a device for coating a workpiece, which comprises at least a deflector means for feeding a material web, downstream of which a pressure means for applying the material web to workpiece surface is arranged, wherein preferred pressure and deflector means comprise cylinders, rollers and/or shoes, wherein the device further comprises at least an energy source, the point of action of which lies in the region of the pressure means, in particular in a region of the pressure means which contacts the material web at least in portions. The device is configured to apply the material web onto the workpiece surface in the inline and/or offline method.