Flexible Platen Lamination Press for Uniform Pressure
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Solution Overview
Problem
Conventional lamination presses face inefficiencies due to deformation of platens, inconsistent pressure distribution, damage to three-dimensional objects, and difficulties in precise temperature control, leading to increased processing times and costs.
Innovation Solution
The use of flexible platens that can flex and pivot to apply uniform pressure, eliminating the need for pressure pads and tooling plates, and allowing for rapid heating and cooling within a single press, enabling efficient lamination of resin panels with improved structural and aesthetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cast iron platens are used in lamination presses, then the platens can provide structural support and heat retention, but they deform under pressure leading to inconsistent pressure distribution and product defects
Solution Approach 1:
The patent replaces rigid cast iron platens with flexible membranes that can conform to the laminate assembly surface. These membranes are thin-walled structures that maintain structural integrity while providing uniform pressure distribution across the entire contact surface, eliminating the deformation issues of conventional rigid platens.
Solution Approach 2:
The invention changes the physical parameters of the platen material from rigid cast iron to flexible membrane materials with different mechanical properties. This parameter change allows the platen to adapt its shape and pressure distribution characteristics while maintaining sufficient structural support through the membrane's elastic properties.
2Manufacturing precision
If tooling plates and pressure pads are added to compensate for platen deformities, then surface uniformity improves, but processing time increases and heat transfer efficiency decreases
Solution Approach 1:
The patent removes the intermediate tooling plates and pressure pads from the lamination system. By using flexible membranes that directly contact the laminate assembly, the invention eliminates these additional components that were previously needed to compensate for platen imperfections, thereby reducing processing steps and improving heat transfer efficiency.
Solution Approach 2:
The flexible membranes provide self-adjusting pressure distribution without requiring additional tooling components. The membranes automatically conform to the laminate surface and distribute pressure uniformly through their inherent flexibility, eliminating the need for separate compensating devices.
3Temperature
If conventional lamination presses heat and cool platens sequentially in separate operations, then temperature control is achieved, but processing time and energy consumption increase
Solution Approach 1:
The patent combines heating and cooling functions into a single integrated platen system. The flexible membrane structure allows for rapid thermal response, enabling the platen to switch between heating and cooling modes without the time penalties associated with conventional sequential operations, thereby reducing overall processing time and energy consumption.
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
This solution reduces processing times, energy consumption, and labor requirements while producing high-quality resin panels with uniform pressure distribution, minimizing damage to materials and extending platen lifespan, thus enhancing manufacturing efficiency and reducing costs.
Implementation Method 1
each incorporating a first flexible plate having a working surface thereon, the first flexible plate being configured to flex relative to the laminate assembly
Implementation Method 2
a heating medium flowing within the plurality of grooves
Implementation Method 3
heating medium flowing within the plurality of grooves configured to heat the flexible plates
Implementation Method 4
a cooling medium flowing within the plurality of grooves
Implementation Method 5
cooling medium flowing within the plurality of grooves configured to cool the flexible plates
Data Source
AI summary
Implementations of the present invention relate to systems, methods, and apparatus for applying heat and pressure to a laminate assembly and to form a unitary product therefrom with increased processing efficiency. One implementation includes an apparatus that can decrease processing time by directly heating and cooling platens that press the laminate assembly. Additionally, the lamination press can allow the platens to flex about the laminate assembly, thereby applying substantially uniform pressure to the laminate assembly.