Laminate Film Curing via Backup Roller Winding
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Solution Overview
Problem
Existing laminate film manufacturing methods suffer from thickness unevenness and wrinkling issues due to the vibration of rollers during the application and curing of ultraviolet curable resin, leading to low accuracy and structural instability in the cured layer.
Innovation Solution
A method involving the continuous transportation of films with a coating solution of active radiation curable resin, sandwiching the coated film between two films, and winding around a backup roller for uniform curing with controlled temperature differences to prevent wrinkling and thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultraviolet curable resin liquid is sandwiched between base film and mold film using rotating rollers, then the resin can be applied and cured, but thickness unevenness occurs in the cured layer and wrinkling occurs in the laminate film
Solution Approach 1:
The patent divides the curing process into two distinct stages: first, the coated film is sandwiched between the base film and mold film to establish uniform thickness; second, the sandwiched structure is wound around a backup roller for curing. This segmentation allows thickness control and curing to occur under different conditions, resolving the contradiction between continuous manufacturing and thickness uniformity.
Solution Approach 2:
The patent performs the sandwiching action before curing to preliminarily establish the uniform thickness of the cured layer. By sandwiching the coated film between the base film and mold film prior to the curing process, the thickness is fixed in advance, preventing thickness unevenness during subsequent curing operations.
2Productivity
If ultraviolet curable resin liquid is sandwiched between base film and mold film using rotating rollers, then the resin can be applied and cured, but wrinkling occurs in the entire laminate film
Solution Approach 1:
The patent separates the sandwiching and curing operations into distinct sequential steps. The sandwiching step establishes structural stability by uniformly夹持ing the coated film, while the curing step occurs after the structure is already stabilized, preventing wrinkling that would occur if both operations happened simultaneously during continuous rotation.
Solution Approach 2:
The mold film acts as an intermediary element that mediates between the resin application and curing processes. By introducing this intermediate layer, the patent enables controlled sandwiching that prevents direct contact and potential wrinkling between the base film and the curing resin, maintaining structural integrity throughout the process.
3Manufacturing precision
If the coated film is irradiated with active radiation while sandwiched between films, then curing occurs, but temperature differences cause wrinkling and thickness variations
Solution Approach 1:
The patent performs the sandwiching action preliminarily before irradiation to establish a stable, uniform structure. By sandwiching the coated film between the base film and mold film before exposing it to active radiation, the patent ensures that temperature differences during curing do not cause wrinkling or thickness variations, as the structure is already fixed in place.
Solution Approach 2:
The patent applies beforehand cushioning by sandwiching the coated film between the base film and mold film prior to irradiation. This preliminary sandwiching creates a cushioned, protected structure that prevents temperature-induced wrinkling and thickness variations during the subsequent curing process, as the films are already constrained in a stable configuration.
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 ensures uniform thickness and prevents wrinkling of the laminate film by maintaining temperature differences within specific limits and using a backup roller for tension and heat management during the curing process, resulting in a stable and accurate cured layer.
Implementation Method 1
irradiating the coated film with active radiation while continuously transporting the first film or the second film to cure the coated film so as to form a cured layer
Data Source
AI summary
A laminate film manufacturing method is capable of preventing thickness unevenness of a cured layer and preventing wrinkling of the entire laminate film. A laminate film is manufactured by applying a coating solution including an active radiation curable resin to a surface of a first film that is continuously transported in an application part to form a coated film in a lamination part, laminating a second film that is continuously transported on the coated film to sandwich the coated film between the first film and the second film, and in a state in which the coated film is sandwiched between the first film and the second film, winding the first film around a backup roller and irradiating the coated film with infrared rays from an ultraviolet irradiation device while continuously transporting the first film to cure the coated film in a curing part so as to form a cured layer.