Hot Press Cushion Material Resolving Releasability and Work Efficiency
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Solution Overview
Problem
Conventional hot press cushioning materials suffer from fuzzing and damage during handling and close contact with heating platens and mirror plates, reducing work efficiency due to their high surface smoothness and lack of releasability.
Innovation Solution
A hot press cushioning material with a core layer of heat-resistant nonwoven fibers and a thin front-side resin layer, along with a back-side rubber layer, is developed to prevent fuzzing and close contact, featuring specific air permeability and bulk density properties to maintain surface irregularities and improve releasability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a synthetic resin film is used as surface layer material to provide releasability, then releasability is improved, but the surface becomes too smooth causing close contact with heating platens and mirror plates, reducing work efficiency
Solution Approach 1:
The surface layer is designed with non-uniform structure: a smooth resin film layer provides releasability, while an underlying porous layer with air permeability of 5-50 cm³/(m²·min) maintains surface irregularities. This local quality differentiation allows the smooth resin surface to prevent adhesion while the porous substrate maintains physical irregularities that prevent close contact with heating platens and mirror plates, thereby resolving the contradiction between releasability and work efficiency
2Reliability
If the surface layer is made smooth to improve releasability, then releasability is improved, but fuzzing and damage occur during handling
Solution Approach 1:
The surface layer is constructed as a composite material system combining a resin film (for releasability) with a porous fiber substrate (for strength). The resin film provides the smooth releasable surface, while the porous substrate with controlled air permeability provides mechanical strength and damage resistance. This composite structure allows the weak smooth surface to coexist with a strong supportive substrate, resolving the contradiction between releasability and surface durability
3Reliability
If a thick resin layer is used to ensure complete coverage, then coverage is improved, but close contact with heating platens occurs, reducing work efficiency
Solution Approach 1:
The resin layer thickness is precisely controlled within 1-50 μm, and the porous substrate's air permeability is controlled within 5-50 cm³/(m²·min). These parameter optimizations ensure the resin layer is thin enough to maintain surface irregularities that prevent close contact, while still providing sufficient coverage. The controlled porosity compensates for the thinness, ensuring complete coverage without excessive thickness, thereby resolving the contradiction between coverage and work efficiency
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 effectively prevents fuzzing and damage, reduces close contact with heating platens and mirror plates, and enhances work efficiency by maintaining surface irregularities and using conductive fillers to reduce static electricity.
Implementation Method 1
The core layer has an air permeability of 5 cm³/(m²·min) to 50 cm³/(m²·min)
Implementation Method 2
heat transfer properties for efficiently transferring heat from the heating platen 51 to the laminate 52
Implementation Method 3
using conductive fillers to reduce static electricity
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
A hot press cushioning material (1) includes: a cushioning material body in the form of a plate; and surface materials (3) provided on the front and back sides of the cushioning material body. The surface material (3) includes a core layer (31) composed of a heat resistant fiber material for a nonwoven structure, and a front-side resin layer (32) covering the entire front side of the core layer. The core layer (31) has an air permeability of 5 cm3·cm-2·s-1 or less and a bulk density of 0.8 g/cm3 or more.