Heated Belt and Drum Lamination for Multi-Layer Soft Goods
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Solution Overview
Problem
Existing laminating apparatuses are limited to securing only two layers together due to the loss of heat by the moving belt, preventing the successful lamination of more than two layers with adhesive between them.
Innovation Solution
A method utilizing a heated moving endless belt and a heated rotating drum to compress and laminate multiple layers together, with both sides of the layered stack being heated to melt the adhesive layers, allowing for the creation of a three-layered laminated soft good.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a heated drum and unheated belt are used to laminate materials, then the footprint of the apparatus is reduced, but only two layers can be secured together because the belt loses residual heat during travel
Solution Approach 1:
The patent changes the thermal parameter of the belt from unheated to heated by adding heating elements that maintain the belt temperature throughout its travel path. This allows the belt to continuously provide heat for bonding multiple layers without losing effectiveness, enabling lamination of three or more layers while maintaining a compact footprint.
Solution Approach 2:
The belt is heated in advance before the materials are applied, ensuring that the entire surface of the belt maintains bonding temperature. This preliminary heating action prevents heat loss during material travel and enables consistent bonding across multiple layers in a compact configuration.
2Device complexity
If only one side of the layered stack is heated, then the apparatus is simpler, but only two layers can be laminated together
Solution Approach 1:
The patent changes the thermal parameter of the belt from unheated to heated by adding heating elements, transforming the heating system from single-sided to dual-sided heating. This enables simultaneous heating of both sides of the layered stack, allowing three or more layers to be laminated together effectively.
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 approach enables the successful lamination of at least three layers with melted adhesive, reducing the footprint of the laminating apparatus and allowing for the production of a versatile laminated soft good suitable for various applications.
Implementation Method 1
Heat from the heated moving endless belt and heat from the heated rotating drum laminating the web of backing material, web of cushioning material and web of ticking material
Implementation Method 2
Heat from the heated moving endless belt melts a web of adhesive between the web of backing material and the web of cushioning material
Implementation Method 3
The layered stack is compressed between the heated moving endless belt and the heated rotating drum
Implementation Method 4
applying a first layer of adhesive between a web of backing material and a first side of a web of cushioning material
Data Source
AI summary
A layered stack is created by placing webs of adhesive on opposite sides of web of cushioning layer and placing outer webs outside the webs of adhesive. An outer surface of a rotating drum is heated by heating oil inside the drum. An endless belt is heated by at least one heater. The layered stack is pulled between the heated endless belt and the heated rotating drum via a motorized drive assembly which rotates the endless belt. Both sides of the layered stack are heated enough to melt each web of adhesive when the layered stack passes between the heated moving endless belt and the heated rotating drum.