Inflatable Former for 3D Membrane Lamination
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Solution Overview
Problem
Existing methods for laminating membranes to three-dimensional articles, such as footwear and clothing, often result in uneven adhesion and inefficiency due to difficulties in applying consistent pressure and activating adhesives effectively.
Innovation Solution
A lamination machine and process utilizing an inflatable former with air permeability, which inflates to apply pressure and heat-activate adhesives uniformly across the article's surface, ensuring even adhesion and breathability of the membrane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional lamination methods are used on three-dimensional articles, then the membrane can be attached to the article, but the adhesion is uneven and the process is inefficient
Solution Approach 1:
The patent uses an inflatable former that inflates with air or gas to apply uniform pressure across the three-dimensional article surface during lamination. This pneumatic system replaces traditional mechanical pressing methods, enabling consistent pressure distribution that achieves even adhesion while maintaining high productivity through automated inflation and heating cycles
Solution Approach 2:
The patent employs temperature and pressure parameter changes by heating the inflatable former to activate adhesives uniformly across the article surface. The controlled thermal and pressure parameters enable consistent bonding conditions throughout the lamination process, resolving the adhesion uniformity issue while maintaining process efficiency
2Strength
If pressure is applied to activate adhesives during lamination, then adhesion strength improves, but the article may deform
Solution Approach 1:
The inflatable former acts as a flexible shell that conforms to the three-dimensional article shape, distributing pressure uniformly across the surface. This flexibility allows the former to apply sufficient pressure for strong adhesion activation while adapting to the article's geometry, preventing deformation that would occur with rigid pressing mechanisms
Solution Approach 2:
The inflatable former provides a cushioning effect by distributing pressure through its flexible structure before adhesive activation occurs. This prior cushioning prevents localized stress concentrations that could deform the article, while still delivering sufficient overall pressure to activate adhesives and achieve strong bonding
3Productivity
If heat is applied to activate adhesives, then bonding efficiency improves, but the membrane breathability may be compromised
Solution Approach 1:
The patent carefully controls the temperature parameter during heating to activate adhesives effectively while staying within limits that preserve membrane breathability. The controlled thermal parameters enable sufficient adhesive activation for strong bonding while avoiding excessive heat that would damage or seal the membrane's breathable structure
Solution Approach 2:
The heating is applied partially and selectively through the inflatable former, providing just enough thermal energy to activate adhesives in the bonding zones without excessive heat exposure to the entire membrane. This partial action achieves efficient adhesive activation while preserving the membrane's breathability in non-bonding areas
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 achieves consistent and strong adhesion of the membrane to the article, maintaining breathability and preventing deformation during the lamination process, with delamination strength values of at least 15 N/50 mm across the entire surface.
Implementation Method 1
heated air is pumped into the former to inflate the former, press the membrane against the target surface, and activate an adhesive
Implementation Method 2
the inflated former applies pressure to press the membrane against the target surface
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Embodiments provide a lamination machine and lamination process for laminating a membrane to a three-dimensional (3D) target surface of an article, such as a footwear article, glove, clothing article, backpack, or other article. The lamination machine may include an inflatable former that is permeable to air. The inflatable former may have a shape that generally corresponds to a shape of the target surface. The membrane and target surface may be arranged on the former, with a heat-activated adhesive disposed between the membrane and the target surface. The lamination machine may further include a pump to pump heated compressed air into the former. The heated compressed air may inflate the former to press the membrane against the target surface and to activate the adhesive to bond the membrane to the target surface.