Fluid Pressure Chamber for Rapid Lamination Cycle
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Solution Overview
Problem
Existing laminating devices require high energy for heating and cooling press pads, leading to increased energy consumption and inefficient cycle times during the laminating process.
Innovation Solution
A laminating device with a pressure chamber filled with a fluid that can be quickly heated and cooled, using a fluid circuit for efficient energy management, allowing for rapid heating and cooling of the laminating sheets and achieving homogeneous pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a press pad is heated and cooled during each lamination cycle, then the lamination process can be performed, but the energy consumption increases and cycle time extends
Solution Approach 1:
The fluid in the pressure chamber is pre-heated or pre-cooled before each lamination cycle. The fluid circuit includes a heater and cooler that prepare the fluid in advance, so when the pressing tool engages with the laminating sheet, the fluid is already at the required temperature, enabling rapid heating or cooling of the laminating sheet without extending cycle time.
Solution Approach 2:
The invention uses a fluid (gas or liquid) in the pressure chamber to transmit thermal energy to the laminating sheet. The fluid circuit system with pumps, heaters, and coolers allows efficient thermal management. The fluid can be rapidly heated or cooled and then pressed against the laminating sheet, transferring heat quickly and uniformly, reducing the time and energy required compared to direct heating of a solid press pad.
2Temperature
If a press pad is used for lamination, then pressure can be applied to the stack, but the heating and cooling process requires significant energy and time
Solution Approach 1:
The invention uses a fluid (gas or liquid) in the pressure chamber to transmit both mechanical pressure and thermal energy to the laminating sheet. The fluid can be rapidly heated or cooled by the fluid circuit system and then pressed against the laminating sheet, transferring heat quickly and uniformly. This hydraulic/pneumatic system allows efficient thermal management with lower energy loss compared to heating and cooling a solid press pad.
Solution Approach 2:
The invention changes the physical state and temperature parameters of the fluid in the pressure chamber rapidly. By controlling the fluid's temperature through the fluid circuit's heater and cooler, the system can quickly transition between heating and cooling modes. The fluid's ability to change temperature rapidly and transmit this thermal energy efficiently reduces energy loss and increases heating/cooling speed.
3Productivity
If a press pad is heated for lamination, then the laminating sheet can be heated, but the subsequent cooling requires additional energy and time
Solution Approach 1:
The fluid circuit system maintains continuous thermal management throughout the lamination process. The fluid is continuously circulated between the heater/cooler and the pressure chamber, ensuring that thermal energy is always available when needed. This continuous action eliminates idle heating or cooling periods, reducing total cycle time and energy consumption.
Solution Approach 2:
The hydraulic/pneumatic fluid system serves dual purposes: applying mechanical pressure to the laminating sheet and transferring thermal energy. The same fluid that applies pressure also heats or cools the laminating sheet, eliminating the need for separate heating and cooling mechanisms. This integrated approach reduces overall energy consumption and process time.
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 enables faster process and cycle times, reduces energy requirements, and ensures even heating and cooling of the laminate composite, improving the efficiency of the laminating process.
Implementation Method 1
the pressure chamber is filled with a fluid during the lamination process... the fluid is supplied and discharged to the pressure chamber via at least one inlet and/or outlet
Implementation Method 2
Direct contact of the hot fluid with the laminating sheet can result in improved heating of the laminating sheet
Implementation Method 3
After lamination, the pressure chamber is emptied and filled with a cool fluid. This allows a quick change to the cooling phase
Implementation Method 4
the pressure chamber can be heated with additional heating elements that are arranged on the pressing tool... filled with a cool fluid
Implementation Method 5
a pressure chamber is formed with a sealing element arranged between them, which is filled with a fluid during the lamination process... achieves a homogeneous pressure distribution on the lamination sheet
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a laminating device and a method for laminating several layers (25) arranged in a stack (24) to form a laminate composite (26) with an upper and lower pressing tool (17, 21) and a laminating sheet (18, 22) assigned to each of the upper and lower pressing tools (17, 21), between which the stack (24) of several layers (25) is arranged to form the laminate composite (26) during a lamination process, whereby a sealing element (23) is provided between the laminating sheet (18, 22) and the pressing tool (17, 21), which, after the laminating sheet (18, 22) and the pressing tool (17, 21) are brought together, forms a pressure chamber (41) that can be filled with a fluid.