Composite Sheet Lamination with Reheating and Dual Roller Stages
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Solution Overview
Problem
Current methods for producing band-shaped composite sheets with metal and plastic layers are inefficient in terms of production speed and prone to delamination during processing.
Innovation Solution
A device and method involving a first laminating device with two rollers, followed by a heating zone to reheat the composite sheet, and a second laminating device with another set of rollers, culminating in a cooling zone, which eliminates the need for double belt presses and enhances adhesion between metal and plastic layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If double belt presses with integrated laminating units are used, then the composite sheets can be produced with metal and plastic layers bonded together, but the production speed is insufficient and economic efficiency is reduced
Solution Approach 1:
The patent divides the laminating process into two separate devices: a first laminating device that performs initial bonding of metal strips with plastic film, and a second laminating device that performs final bonding to create the composite sheet. This segmentation allows each device to be optimized for its specific function, enabling higher production speeds while maintaining bond quality, thereby resolving the contradiction between productivity and device complexity.
2Reliability
If traditional lamination methods are used, then the metal sheets and plastic layer can be bonded, but the adhesion is insufficient and delamination occurs during further processing
Solution Approach 1:
The first laminating device performs preliminary bonding of the metal strips with the plastic film before the final lamination step. This preliminary action creates an initial adhesive bond that prevents delamination during handling and further processing, while the two-stage process overall enables higher production speeds by allowing parallel processing and optimized parameters for each stage.
3Reliability
If heating zones are added after lamination to reheat composite sheets, then delamination risk is reduced, but the device complexity increases
Solution Approach 1:
The heating zone is integrated into the lamination process flow, combining the heating function with the existing lamination devices. The first laminating device is followed by a heating zone that reheats the composite sheet to improve bond stability, and this is further integrated with the second laminating device. This merging approach provides the reliability benefit of reduced delamination while minimizing additional device complexity through integrated design.
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
This approach significantly increases production speed and reduces the risk of delamination, allowing for more efficient and stable manufacturing of composite sheets.
Implementation Method 1
a first heating zone with heating means for reheating the composite sheet to a lamination temperature in the first lamination slit after the first lamination step
Implementation Method 2
a cooling zone is arranged after the second lamination slit
Implementation Method 3
preheating the metal strips and the plastic film before they are fed to a first laminating device
Data Source
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AI summary
The invention relates to a device (1) and a method for producing a band-shaped composite sheet (1) which has at least two outer metal cover sheets and at least one plastic layer arranged between the cover sheets (7, 8), comprising at least one first lamination device (12) for laminating the metal cover sheets (7, 8) with the at least one plastic layer (6) arranged between the metal cover sheets, which lamination device has at least two lamination rollers (12a, 12b) forming a lamination gap, wherein, in the process direction after the first lamination gap, a first heating zone (13, 26, 40) is provided with heating means for renewed heating up of the composite sheet (2, 32, 45) after the first lamination step in the first lamination gap to a lamination temperature, and a second lamination device (14, 27, 43) is arranged in the process direction after the first heating zone (13, 26, 40) and has a second lamination gap formed by at least two lamination rollers (14a, 14b, 27, 40), and a cooling zone (16, 30, 44) is arranged after the second lamination gap.