Discontinuous Laminate Production With Separate Cooling Press
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Solution Overview
Problem
Conventional laminate production processes face challenges with inefficient energy use, high heat capacity in press platens, and surface indentations due to insufficient cooling, leading to reduced surface quality and longer cycle times.
Innovation Solution
A device and method for discontinuous laminate production involving a hot press, cooling press, and transfer device with manipulation units for substrate packages and laminates, utilizing passive cooling and optimized transport mechanisms to minimize waiting times and improve surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If alternating heating and cooling of press platens is used, then cooling speed is improved, but device complexity and energy consumption increase
Solution Approach 1:
The press system is divided into two independent presses: a hot press for heating and laminating, and a cooling press for cooling. This segmentation allows each press to be optimized for its specific function, avoiding the complexity of alternating temperature systems while achieving rapid cooling through dedicated cooling infrastructure.
Solution Approach 2:
A transfer device acts as an intermediary between the hot press and cooling press, transporting the laminate between them. This mediator enables the decoupling of heating and cooling processes, allowing rapid cooling without requiring the hot press platen to alternate temperatures, thus simplifying the press platen design.
2Temperature
If press platens are made thin and elastic for temperature alternation, then thermal response is improved, but structural rigidity and impact resistance deteriorate
Solution Approach 1:
The pressing function is segmented into two separate presses with different platen configurations. The hot press platen can be optimized for thermal response, while the cooling press platen maintains structural rigidity. This eliminates the need for thin, elastic platens that compromise strength, as the cooling function is performed in a separate press with appropriately designed rigid platens.
3Loss of time
If laminates are removed at high temperature after short cooling, then cycle time is reduced, but surface quality deteriorates due to indentations
Solution Approach 1:
The thermal processing is segmented into two distinct stages in separate presses: heating/laminating in the hot press, and cooling in the cooling press. This allows the laminate to be cooled sufficiently to achieve proper surface quality and plasticization before removal, without extending the overall cycle time excessively, as the cooling press operates independently and efficiently.
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 rapid cycle times, reduced energy consumption, and enhanced surface quality by minimizing pressure-free waiting times and optimizing laminate handling, resulting in efficient laminate production.
Implementation Method 1
a hot press for pressing a substrate package by means of pressure and heat to form a laminate
Implementation Method 2
a cooling press for cooling the laminate
Data Source
AI summary
The invention relates to a device and a method for the discontinuous production of a laminate from several substrates in a hot press, comprising: a staging station (1) for a substrate package (5) consisting of several substrates, a hot press (2) for compressing a substrate package (5) by means of pressure and heat to form a laminate (6), a cooling press (3) for cooling the laminate (6), and a storage station (4) for the laminate (6), wherein at least one transfer device (10) is arranged for transporting the substrate packages (5) and the laminates (6) between the staging station (1), the hot press (2), the cooling press (3), and the storage station (4), and wherein a manipulation unit (8) of a first type for the substrate package (5) and two manipulation units (9) of at least a further type for laminates (6) are arranged in the transfer device (10).A special feature of the invention is the arrangement of a separate cooling press in conjunction with the transfer unit to optimize the cycle times (1024).