Continuous Flame Lamination of Rigid Carrier and Foam Composite
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Solution Overview
Problem
The production of multi-layer material structures is complex and economically uneconomical due to the need for manual bonding of rigid and less rigid materials, making continuous production impossible.
Innovation Solution
A method involving inline roll flame lamination, where a fiber-reinforced carrier material with higher flexural rigidity is continuously connected to a soft, foam-reinforced composite material using a heat source, such as an open flame burner, allowing for direct and continuous bonding by applying pressure, ensuring minimal mechanical stress and straight material conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual bonding methods are used for multi-layer material structures, then bonding flexibility is maintained, but production efficiency is low and continuous production is impossible
Solution Approach 1:
The patent implements continuous production by passing both the rigid substrate and flexible composite material through a continuous flame lamination process. The materials are fed continuously through a bonding zone where adhesive is applied and activated by flame, eliminating the need for intermittent manual bonding operations and enabling sustained high-speed production.
Solution Approach 2:
The patent replaces manual mechanical bonding operations with an automated flame lamination system. The adhesive is activated by thermal energy from a flame source rather than mechanical pressure alone, and the materials are conveyed through the process using roller mechanisms, substituting human-operated mechanical assembly with an automated thermal-mechanical system.
2Strength
If mechanical stress is applied during bonding of rigid carrier material, then bonding pressure is achieved, but damage to substrate or detachment of composite material occurs
Solution Approach 1:
The patent changes the bonding mechanism from purely mechanical pressure to a thermal-chemical process. The adhesive is activated by flame heating, which alters its physical and chemical properties to enable bonding. This parameter change from mechanical to thermal activation allows bonding without subjecting the rigid carrier material to damaging mechanical stresses.
Solution Approach 2:
The patent introduces adhesive material as an intermediary between the rigid carrier substrate and the flexible composite material. The adhesive acts as a bonding medium that can be activated by flame, creating a strong bond without requiring direct mechanical stress between the substrate and composite material, thus preventing damage and detachment.
3Ease of operation
If deflection rollers and guide rollers are used to convey materials, then material guidance is achieved, but mechanical stress and material damage occur
Solution Approach 1:
The patent uses curved or rounded roller surfaces instead of sharp-edged deflection and guide rollers. The curved surfaces of the rollers gently guide the materials through the bonding zone without creating stress concentration points, eliminating the mechanical stress and damage associated with traditional angular guide rollers while maintaining effective material guidance.
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 the economical and continuous production of multi-layer material structures as web-like materials, reducing production costs and avoiding mechanical stress-related issues, while maintaining the structural integrity of the carrier material.
Implementation Method 1
The adhesive material is heated by means of a heat source. The heat source is designed as a burner with an open flame.
Implementation Method 2
The heated adhesive material enables the direct bonding of the composite material to the carrier material.
Implementation Method 3
The bonding unit enables the direct and continuous bonding of the carrier material to the composite material by applying pressure such that the materials are pressed together.
Implementation Method 4
The composite material has, at least in certain areas, an adhesive material that is heated by means of a heat source. The heated adhesive material enables the direct bonding of the composite material to the carrier material.
Data Source
Figure 1
AI summary
A device for the continuous production of a multi-layer material structure (10) comprises a first feeding unit (2) for feeding carrier material (3), a second feeding unit (6) for feeding a composite material (7) which has at least in some areas a foam-like adhesive material, a heat source (21) for heating the adhesive material and a joining unit (9) for continuously joining the heated composite material (7) with the carrier material (3) to form the multi-layer material structure (10), wherein the carrier material (3) has a higher flexural stiffness than the composite material (7).