Film Lamination via Electrostatic Powder Adhesion
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Solution Overview
Problem
Existing laminating methods face challenges with expensive devices and uneven powder application due to the need for electrostatic charging of powders, particularly in large working widths, and the sensitivity of water-based adhesives to frost.
Innovation Solution
A laminating method and device that electrostatically charge an endless film before rolling it up, allowing for uniform powdering without electrical adjustments, and use a heating device to melt hot-melt adhesive for full-surface adhesion, with a pressing device ensuring continuous high-speed production and low susceptibility to failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrostatic charging of powder is used for application, then uniform powder application is achieved, but device complexity and cost increase significantly
Solution Approach 1:
Instead of charging the powder to achieve uniform application, the invention inverts the approach by charging the film substrate. The charged film then attracts and uniformly distributes the uncharged powder across its surface, eliminating the need for complex electrostatic powder charging devices while achieving uniform application.
Solution Approach 2:
The charged film serves itself by automatically attracting and distributing the powder through its electrostatic charge. The film's own charge property performs the function of uniform powder distribution without requiring external electrostatic application devices, reducing system complexity.
2Ease of manufacture
If water-based adhesive is used for lamination, then cost is reduced, but sensitivity to frost increases
Solution Approach 1:
The invention changes the chemical composition parameter of the adhesive from water-based to solvent-based (such as toluene-based). This parameter change eliminates the frost sensitivity issue while maintaining cost-effectiveness, as solvent-based adhesives do not contain the water that freezes at low temperatures.
3Strength
If thermoplastic coating is applied to laminating film, then bonding is improved, but film cost increases significantly
Solution Approach 1:
The invention extracts the thermoplastic coating step from the traditional process. Instead of coating the film with thermoplastic before lamination, the patent uses a solvent-based adhesive that is applied directly to the film surface, eliminating the need for thermoplastic coating while maintaining bonding strength.
Solution Approach 2:
The invention replaces expensive thermoplastic-coated films with uncoated films that use a cost-effective solvent-based adhesive. The adhesive is applied in a cost-effective manner and evaporates or cures to provide bonding, eliminating the need for expensive thermoplastic coating materials.
4Manufacturing precision
If electrostatic charging adjustment is required for powder application, then application uniformity is achieved, but production speed decreases
Solution Approach 1:
The invention eliminates the need for electrostatic charging adjustment by inverting the charging approach. Instead of adjusting electrostatic fields to control powder application, the system uses a charged film that passively attracts and distributes powder uniformly, allowing for faster production without precision adjustments.
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
Enables reliable, fast, and cost-effective continuous production of laminated printed goods with uniform adhesion, reducing device complexity and maintenance costs, and allowing for independent film production and storage.
Implementation Method 1
a charging means (4) for electrostatically charging the supplied film
Implementation Method 2
a heating device (2) for heating the film covered with the powdered adhesive
Implementation Method 3
a pressing device (3) for pressing the film provided with the heated adhesive onto the has to be laminated printed matter
Data Source
Figure 1
AI summary
The method involves applying powdered adhesive (K) on a side of a film (F) by an applicator (1). The film applied with the adhesive is heated by a heating device (2), and the film provided with the heated adhesive is pressed on a print product (D) by a pressing device (3). The film is electrostatically charged before the powdered adhesive is applied. The film is processed to a rolled endless product, and the film is electrostatically charged during rolling of the film by rolling. The film is transported and/or stored as the rolled endless product. An independent claim is also included for a laminating device for laminating a print product.