Partially Vulcanized FKM Press Pad for Hot Press Adaptation
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Solution Overview
Problem
Existing press cushions for heating presses face challenges in adapting to individual geometric and dimensional variations in press systems, leading to uneven pressure distribution, premature wear, and surface defects in coated materials, due to their uniform thickness and limited ability to adjust to different thermal conductivities and thickness tolerances.
Innovation Solution
A press cushion with a partially crosslinked FKM rubber material and a metal wire mesh core, which undergoes final crosslinking and vulcanization in the press system, allowing for adaptation to specific dimensions and thermal conductivity needs, and can be fixed directly to the press plates or with a separating film, ensuring even pressure distribution and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press pads are made with uniform thickness, then manufacturing is simplified, but they cannot compensate for geometric deviations in press plates leading to uneven pressure distribution
Solution Approach 1:
The press pad is designed with variable thickness across its surface, where the thickness is adapted to the specific geometric deviations of the press plates. This allows different regions of the press pad to compensate for local dimensional deviations, ensuring uniform pressure distribution while maintaining manufacturing feasibility through a systematic thickness variation approach.
2Strength
If press pads are made from traditional textile fabrics, then they provide cushioning properties, but they have limited thermal conductivity and cannot quickly transfer heat
Solution Approach 1:
The press pad combines a metal mesh carrier material with an FKM rubber padding layer. The metal mesh provides high thermal conductivity for rapid heat transfer, while the FKM rubber layer maintains the necessary cushioning properties and pressure distribution. This composite structure resolves the contradiction between thermal conductivity and cushioning resilience.
3Manufacturing precision
If press pads are made with varying thickness to compensate for press deviations, then pressure distribution improves, but manufacturing complexity increases
Solution Approach 1:
The press pad utilizes controlled variation in the thickness parameter of the FKM rubber layer while maintaining a consistent metal mesh carrier. This parameter change allows the press pad to adapt to geometric deviations in press plates, improving pressure distribution without requiring complex multi-component structures or assembly processes.
4Ease of operation
If press pads are attached directly to press plates, then fixation is simplified, but removal and replacement becomes difficult
Solution Approach 1:
The press pad is pre-formed with a specific thickness profile that compensates for press plate geometric deviations before installation. This preliminary preparation allows the press pad to be easily attached and removed without requiring complex fixation mechanisms, while maintaining its pressure distribution function throughout multiple press cycles.
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 extends the lifespan of press cushions, improves surface quality by compensating for thickness and thermal conductivity variations, and simplifies attachment, reducing wear and tear while maintaining high temperature resistance and mechanical strength.
Implementation Method 1
the final crosslinking or final vulcanization of the press pad takes place in the single- or multi-stage heating press under pressure and temperature
Implementation Method 2
the final crosslinking or final vulcanization of the press pad takes place in the single- or multi-stage heating press under pressure and temperature
Implementation Method 3
They quickly conduct heat from the heating plate to the press plate and then to the surface of the workpiece
Data Source
AI summary
A single- or multi-daylight hot press has at least one heating plate (8), at least one pressing plate (9) and at least one press pad (1), which is arranged between the heating plate (8) and the pressing plate (9) and comprises a supporting material (2) in the form of a metal mesh and a pad layer (7), consisting of an FKM rubber material. In order to achieve very good adaptation of the press pad (1) to the conditions of the press plant, it is proposed that the press pad (1) is installed in the single- or multi-daylight hot press in such a state in which the pad layer (7) comprises a partially crosslinked or partially vulcanized FKM rubber material and that the final crosslinking or final vulcanizing of the press pad (1) is performed in the press plant. A method for producing a press pad (1), use of the same and also a press pad (1) are also disclosed.