Jig Return Line for Precise Film Lamination on Varied Shapes
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Solution Overview
Problem
Conventional vacuum forming methods require heavy jigs that are cumbersome to move and replace, making it difficult to efficiently laminate sheet-shaped decorating materials onto resin base materials with various shapes.
Innovation Solution
A film forming apparatus with a forming line for cleaning, lamination, and removal operations, and a jig returning line for reusing jigs, enabling efficient film formation on objects with varying shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy jigs are used to support resin base materials, then the stability and precision of film lamination is improved, but the ease of operation and productivity deteriorate due to the cumbersome movement and replacement of jigs
Solution Approach 1:
The system is divided into two independent lines: a forming line for film lamination and a returning line for jig transport. This segmentation allows the forming line to maintain high precision with stable jigs while the returning line handles the movement and replacement operations separately, resolving the contradiction between stability during operation and ease of movement.
Solution Approach 2:
The returning line acts as an intermediary system that manages jig logistics between forming cycles. It includes conveyors and storage mechanisms that handle jig movement independently from the film formation process, allowing heavy jigs to remain stable during lamination while being easily transported when not in use.
2Adaptability or versatility
If jigs are replaced frequently to accommodate various resin base material shapes, then the adaptability is improved, but the productivity and time efficiency deteriorate due to the time-consuming replacement process
Solution Approach 1:
The returning line prepares and positions required jigs in advance before they are needed on the forming line. By pre-positioning jigs according to the production schedule and material types, the system minimizes waiting time and ensures immediate availability of appropriate jigs, maintaining both adaptability and productivity.
Solution Approach 2:
While one jig is being used on the forming line, another jig can be prepared or moved on the returning line simultaneously. This continuous operation eliminates idle time and ensures that jig replacement or switching does not interrupt the film formation process, maintaining high productivity across different material shapes.
3Ease of operation
If a spacious facility is provided for conventional spray painting, then the ease of operation is improved, but the energy consumption and facility cost increase significantly
Solution Approach 1:
The patent replaces the conventional spray painting mechanical system with a vacuum film formation system. Instead of using spray equipment that requires large facilities for mist dispersion and processing, the invention uses vacuum-based film lamination that can be performed in a compact chamber, significantly reducing energy consumption and facility requirements while achieving similar decorative results.
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
Enables efficient decoration of objects by allowing for the reuse of jigs and optimizing the film formation process, reducing operational complexity and improving productivity.
Implementation Method 1
a vacuum chamber configured to be capable of forming a vacuum state
Data Source
AI summary
A film forming apparatus comprising: a first forming line for conveying a target object in a state of being placed on a jig, and performing a cleaning operation of cleaning the target object, a lamination operation of laminating a film onto the target object after the cleaning operation, and a removal operation of removing a portion of the film laminated onto the target object after the lamination operation; and a jig returning line for returning the jig used on the first forming line from an exit of the first forming line to an entrance of the first forming line.