Integrated Laminating Tool for Rapid Thermal Cycling
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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 maintenance costs due to wear and tear, and complicate the lamination process with uneven stacks.
Innovation Solution
A laminating tool with an embossing plate and carrier plate featuring a rib-shaped supporting structure surrounded by an outer wall, allowing for rapid heating and cooling through medium flow, which also compensates for stack unevenness with integrated pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure pads are used to compensate for stack unevenness and apply uniform pressure, then lamination quality is improved, but energy consumption increases due to heating and cooling requirements
Solution Approach 1:
The patent combines the pressure application function and the temperature control function into a single integrated laminating tool. The tool includes a housing with heating elements and cooling channels built-in, eliminating the need for separate pressure pads. This integration reduces the number of components that require independent heating and cooling, thereby reducing overall energy consumption while maintaining lamination quality.
Solution Approach 2:
The laminating tool is designed as a multi-functional device that simultaneously performs pressure application, heating, and cooling functions. The housing serves multiple purposes: structural support, pressure transmission, and thermal management through integrated channels. This multi-functionality eliminates the need for separate pressure pads and their associated thermal management systems, reducing energy consumption.
2Manufacturing precision
If pressure pads are used to apply uniform pressure, then lamination quality is improved, but maintenance costs increase due to wear and tear
Solution Approach 1:
The patent integrates the pressure application function directly into the laminating tool housing, eliminating separate pressure pads. The housing itself transmits pressure through its structure, which does not subject to wear in the same way soft pads do. This integration removes the wear-prone components, thereby reducing maintenance requirements and costs while maintaining consistent pressure application for quality lamination.
3Temperature
If press plates and pressure pads are heated and cooled, then lamination process is enabled, but cycle time increases
Solution Approach 1:
The patent combines heating and cooling channels within the same laminating tool housing, allowing for rapid thermal response. The integrated design reduces thermal mass compared to separate press plates and pads, enabling faster heating and cooling cycles. This reduces the overall cycle time while maintaining the necessary temperature control for the lamination process.
Solution Approach 2:
The laminating tool incorporates separate heating channels and cooling channels that can operate independently or in sequence. This segmentation allows for optimized thermal management where heating and cooling can be targeted to specific regions or activated at different times, reducing unnecessary thermal processing and thereby reducing cycle time.
4Force
If multiple components (press plates and pressure pads) are used, then pressure application is effective, but device complexity increases
Solution Approach 1:
The patent merges the press plate and pressure pad functions into a single integrated laminating tool. The housing structure itself serves as the pressure transmission element, eliminating the need for separate press plates and pressure pads. This reduces the number of components from three (press plate, pressure pad, and support structure) to one integrated unit, simplifying the device while maintaining effective pressure application through the housing's structural design.
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 energy consumption by quick heating and cooling, minimizes maintenance, and simplifies the lamination process with efficient pressure distribution, enabling faster cycle times and improved handling reliability.
Implementation Method 1
heating and cooling using a flowable medium
Implementation Method 2
heating and cooling using a flowable medium
Implementation Method 3
the heating and cooling medium can also generate the necessary pressure within the laminating tool
Data Source
Figure 1~4
Figure 5~7
Figure 8~10b
AI summary
The invention relates to a laminating tool, to a laminating device, and to a method for laminating a plurality of layers arranged in a stack (36) in order to form a laminated composite, wherein a laminating tool (11), having a stamping plate (12), a carrier plate (16), and a supporting structure (17) arranged therebetween, is provided, which laminating tool is surrounded by an outer wall (19) closed toward the outside and forms a closed inner volume and has at least one supply (21) and one discharge (22) for at least one medium that flows through the inner volume.