Curved Vacuum Bonding Jig for Flat-Plate Lamination
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Solution Overview
Problem
Conventional bonding jigs for flat-plates, such as those used in plate glass lamination, often result in air bubble formation and uneven thickness due to complex structures and inadequate pressure distribution, leading to suboptimal lamination accuracy and productivity.
Innovation Solution
A flat-plate bonding jig with a curved, outward-facing surface featuring suction holes for vacuum adsorption, connected by a main body with communication means for uniform suction pressure, allowing for smooth curvature and consistent pressure application during the lamination process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding jigs with complex structures are used, then bonding capability is achieved, but air bubble formation occurs and lamination accuracy deteriorates
Solution Approach 1:
The bonding jig is divided into multiple suction units with individual suction holes, allowing independent control of suction force in different regions. This segmentation enables precise pressure distribution across the bonding surface, preventing air bubble formation while maintaining reliable bonding capability.
Solution Approach 2:
Different regions of the bonding jig are equipped with suction holes of varying sizes and densities tailored to local requirements. Areas prone to air bubble formation have enhanced suction capabilities, while other regions maintain appropriate pressure for bonding, achieving both reliability and precision.
2Reliability
If complex structure bonding jigs are used, then bonding function is achieved, but pressure distribution becomes uneven
Solution Approach 1:
The bonding surface is segmented into multiple independent suction zones, each with controllable suction force. This allows independent adjustment of pressure in each zone to achieve uniform overall pressure distribution while maintaining effective bonding function.
Solution Approach 2:
The suction force in different regions is adjusted by changing parameters such as suction hole diameter, density, and suction pressure levels. This enables precise control of pressure distribution uniformity across the bonding surface.
3Reliability
If conventional bonding methods are used, then lamination is achieved, but productivity is reduced due to rework
Solution Approach 1:
Traditional mechanical pressure application methods are replaced with a vacuum suction system. This substitution enables more uniform and controllable pressure distribution, eliminating air bubble formation and the need for rework, thereby improving productivity while achieving reliable lamination.
4Device complexity
If simple bonding jigs are used, then structure complexity is reduced, but air bubble suppression capability is insufficient
Solution Approach 1:
A vacuum suction system is integrated into the bonding jig design, using pneumatic principles to create controlled negative pressure zones. This effectively suppresses air bubble formation during bonding while maintaining relatively simple overall structure through the use of standardized suction components.
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 described jig effectively suppresses air bubble formation and ensures accurate lamination by maintaining uniform pressure and curvature, enhancing the productivity and quality of flat-plate laminated bodies.
Implementation Method 1
a second surface that is on an opposite side of the first surface, has a plurality of suction holes for vacuum adsorbing a flat-plate
Data Source
AI summary
Provided is a jig having a structure that differs from conventional jigs and enables flat plates to be bonded while suppressing an air bubble formation. A flat-plate bonding jig is provided with the following: a first surface; a second surface that is on the opposite side of the first surface, has a plurality of suction holes for sucking a flat-plate, and is curved outward in a substantially arc shape; a main body connecting the first surface and the second surface; and a communication means that is disposed in the main body and allows the suction holes to communicate with a suction means.