Multi-Layer Film Bonding Machine with Adjustable Nip
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Solution Overview
Problem
Conventional systems for bonding multiple layers of film require multiple machines connected in series, leading to cumbersome and expensive setups with high energy consumption, especially when bonding three or more films using solventless adhesives.
Innovation Solution
A compact machine design that can bond up to three layers of film simultaneously using solventless adhesive, featuring three pay-out units with spreader/applicator units and adjustable bonding zones to apply adhesive and pressure optimally, allowing for flexible bonding configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple bonding machines are connected in series to bond three or more films, then the bonding capability is improved, but the device complexity and space requirements increase significantly
Solution Approach 1:
The patent combines multiple bonding functions into a single integrated machine that can bond three films simultaneously. The machine includes three pay-out units, three spreader/applicator units, and one bonding unit that operates together to bond multiple films in a single pass, eliminating the need for multiple separate bonding machines connected in series.
Solution Approach 2:
The invention transitions from a sequential bonding process (multiple machines in series) to a parallel bonding process (single machine bonding all layers simultaneously). This dimensional change in the process flow allows all three films to be bonded at the same time rather than one after another, reducing overall device complexity.
2Adaptability or versatility
If multiple bonding machines are connected in series to bond three or more films, then the bonding capability is improved, but the space requirements increase significantly
Solution Approach 1:
The patent merges multiple bonding machines into a single compact unit that performs all bonding operations in one location. The integrated design with three pay-out units, three spreader/applicator units, and one bonding unit occupies significantly less floor space than multiple separate machines would require.
3Adaptability or versatility
If multiple bonding machines are connected in series to bond three or more films, then the bonding capability is improved, but the energy consumption increases significantly
Solution Approach 1:
The patent combines multiple bonding operations into a single machine that runs continuously, bonding three films simultaneously in one pass. This eliminates the need for multiple machines to operate sequentially, reducing total energy consumption while maintaining bonding capability.
Solution Approach 2:
The machine is designed to operate continuously with all three films being bonded simultaneously in a single continuous process. This continuous operation is more energy-efficient than stopping and starting multiple separate machines, as the bonding unit maintains steady operation throughout the process.
4Productivity
If conventional bonding machines are used to bond films at high speed, then the productivity is improved, but the energy consumption increases
Solution Approach 1:
The patent integrates three film bonding operations into a single high-speed machine that processes all three films simultaneously. This combined approach maintains high productivity while reducing energy consumption compared to running three separate machines, as the single machine operates more efficiently at continuous high speed.
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 machine significantly reduces energy consumption and space requirements while enabling efficient bonding of films with different characteristics, offering flexibility in manufacturing various types of multi-layer films with reduced operational costs and complexity.
Implementation Method 1
Each unit includes an adhesive tank and means for picking up said adhesive and transferring it in a thin layer to an applicator roller which moves in contact with the drum
Implementation Method 2
spreads a small amount of adhesive (1-2 g/m2) onto the surface of the film as it advances
Implementation Method 3
bonded to the preceding film in a bonding unit
Implementation Method 4
bonding different films it is very compact, being far smaller than conventional systems which, in order to bond several layers, require the same number of bonding machines as the number of layers, connected in series
Data Source
AI summary
A machine for bonding layers in a film includes first pay-off unit to unwind a first layer of the film, a second pay-off unit to unwind a second layer of the film, a third pay-off unit to unwind a third layer of the film, a bonding zone to join the various layers of film together, and a winding unit including a reel onto which the bonded film is wound, the bonding zone including at least one bonding unit, the pressing roller being fitted with at least an hydraulic actuator which brings it in contact with the layers of film on the bonding calender, the presser roller and the hydraulic actuator being mounted on a nip rotating around the axis of the bonding calendar so as to vary the position of the point of contact between the presser roller and the calender and hence to vary the breadth of the contact arc, along the surface of the calender, in which the layers are overlapped.