Multi-Layer Laminate Splicing with Delamination and Layer Rebuild
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Solution Overview
Problem
Existing automated splicing systems for multi-layered laminated materials are inefficient and require manual labor, leading to low process efficiency, material waste, and increased operational costs due to the need for manual splicing and complex re-lamination processes.
Innovation Solution
A method and apparatus for splicing multi-layered laminated materials by simultaneously joining outer layers and then removing and replacing inner layers, using automated or manual processes, allowing for a continuous manufacturing process with minimal downtime and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual splicing is performed on multi-layered laminated materials, then each layer can be joined individually, but the process requires the reels to be stationary for lengthy periods, reducing productivity
Solution Approach 1:
The multi-layered laminated material is divided into individual layers for separate splicing operations. Each layer is separated, spliced independently with proper alignment, and then reassembled. This segmentation allows precise control over each layer's joining process while maintaining overall productivity through systematic organization of the splicing sequence.
2Productivity
If automated splicing systems are used, then splicing speed increases, but they only join outer surfaces and cannot properly join multi-layer raw material reels
Solution Approach 1:
The splicing system incorporates dynamic layer separation and reassembly mechanisms that adapt to multi-layered materials. The apparatus dynamically adjusts to separate layers during splicing, applies joining forces to appropriate layers, and maintains proper alignment throughout the process. This dynamic capability enables automated high-speed splicing while ensuring complete and precise joining of all layers.
3Ease of operation
If a festoon buffer is created to maintain continuous process motion during splicing, then downstream processes can remain in motion, but very large capacity festoons are required for high speeds
Solution Approach 1:
The splicing apparatus performs preliminary layer separation, alignment, and joining operations in advance, enabling quick splicing cycles that minimize the need for large festoon buffers. By preparing and executing splicing operations efficiently beforehand, the system reduces the required festoon capacity while maintaining continuous downstream process motion at high speeds.
4Stability of the object's composition
If outer layers are re-laminated after internal splicing, then the original raw material construction is recreated, but additional costly equipment and complex processes are required
Solution Approach 1:
The splicing apparatus merges the internal layer splicing operation with the outer layer re-lamination process into a single integrated operation. By combining these steps, the system recreates the original raw material construction without requiring separate re-lamination equipment or complex multi-step processes, thereby maintaining material integrity while reducing device complexity.
Data Source
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AI summary
The present invention relates to a method for splicing an upstream section and a downstream section of a multi-layered laminated sheet material wherein each section of the material comprises at least three layers each having first and second surfaces and wherein the at least three layers comprise first and second outer layers and at least one inner layer located between the first and second outer layers, comprising the steps of a) splicing together the upstream and downstream sections of both the first and second outer layers with a splicing material; b) removing the first outer layer from the multi-layered laminated sheet material to expose a surface of an inner layer; c) splicing the upstream and downstream sections of the exposed inner layer with a splicing material; and d) applying a replacement first outer layer to the exposed surface of the inner layer. A spliced multi-layered laminated sheet material produced according to the method is also provided. Also provided is an apparatus for splicing two sections of a multi-layered laminated sheet material wherein each section of the material comprises at least three layers each having first and second surfaces and wherein the at least three layers comprise two outer layers and at least one inner layer located between the two outer layers, the apparatus comprising: a first splicer configured to apply a splicing material to the two outer layers of the multi-layered laminated sheet material, a delaminator configured to remove a first outer layer, a second splicer located downstream of the delaminator configured to apply a splicing material to the exposed inner layer and an applicator located downstream of the second splicer configured to reapply an outer layer to the exposed inner layer.