Film Patterning System With Segmented Screen Molds
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Solution Overview
Problem
Existing film patterning systems with co-axially stacked metal screens face challenges in precision and cost due to the complexity of manufacturing seamless cylindrical metal screens and difficulties in assembling them, requiring high precision and increased manufacturing costs.
Innovation Solution
A film patterning system with adjustable rotary members and seamless metal or heat-resistant plastic screen molds that can be easily mounted and tightly trained, allowing for precise patterning of plastic films with adjustable axes and simultaneous patterning capabilities using multiple screen molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If co-axially stacked seamless metal screens are used for film patterning, then patterning precision is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The screen mold is divided into multiple separable screen elements that can be stacked one above the other. Each screen element can be manufactured independently and then assembled, reducing the complexity of manufacturing a single large seamless screen while maintaining patterning precision.
Solution Approach 2:
The screen elements are designed with adjustable positioning mechanisms that allow for dynamic alignment and spacing adjustments. This enables the system to maintain precise patterning while accommodating manufacturing tolerances and facilitating easier assembly compared to fixed seamless screens.
2Manufacturing precision
If co-axially stacked seamless metal screens are used for film patterning, then patterning precision is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the screen mold into multiple smaller screen elements, each element can be manufactured more economically using standard fabrication processes. The modular design allows for simpler manufacturing compared to producing a single large seamless screen, thereby reducing overall manufacturing cost while maintaining precision.
Solution Approach 2:
The screen elements can be manufactured from cost-effective materials and designed as replaceable components. If a screen element wears out or becomes damaged, only that individual element needs to be replaced rather than the entire seamless screen, reducing long-term manufacturing and maintenance costs.
3Manufacturing precision
If co-axially stacked seamless metal screens are used for film patterning, then patterning precision is improved, but assembly difficulty increases
Solution Approach 1:
The segmented screen elements are designed with standardized interfaces and mounting features that simplify assembly. Each element can be independently positioned and secured, making the assembly process more straightforward compared to installing a single large seamless screen, while still achieving the required patterning precision through careful alignment of the modular 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 system reduces manufacturing complexity and costs by facilitating precise mounting and patterning of plastic films with adjustable axes, enabling efficient and cost-effective production of patterned films with high precision.
Implementation Method 1
a suction roll or first rotary member having a laminated, seamless, cylindrical metal molding element for vacuum perforation of plastic films
Implementation Method 2
a heated roll or second rotary member spaced apart from the suction roll and having a smooth cylindrical heating element for softening a plastic film
Data Source
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AI summary
A film patterning system includes: a first rotary member (3) having a first shaft (30) that defines a first axis, and a cylindrical first screen mold (31) that is rotatable about the first axis; a second rotary member (4) spaced apart from the first rotary member, having a second shaft that defines a second axis parallel to the first axis, and rotatable about the second axis; a second screen mold (5) trained on the first and second rotary members and circumferentially stacked on the first screen mold; and a suctioning box (7) mounted in the first rotary member for suctioning the film that is guided onto the second screen mold.