Laminating Device Overlap Control to Protect Adhesive Layers
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Solution Overview
Problem
In laminating devices where a member with an adhesive layer contacts rollers, adhesive layers can cause operational abnormalities due to contact with components in the laminating unit.
Innovation Solution
A laminating device with a controller that orchestrates the lamination process to ensure the adhesive layer of a first member is protected by overlapping a second member's tailing end and a third member's leading end, reducing contact with rollers, using sensors to detect ends and guide members for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first member with adhesive layer is laminated using conventional sequential method, then the lamination process is simple, but the adhesive layer contacts rollers causing operational abnormalities
Solution Approach 1:
The lamination process is divided into multiple phases: first laminating the first member with the leading end of the second member, then laminating the remaining portion of the second member and the third member. This segmentation allows the adhesive layer to be protected by overlapping members during different stages, preventing contact with rollers while maintaining process control.
Solution Approach 2:
The leading end of the second member is preliminarily laminated to the first member before the rest of the second member and third member are laminated. This preliminary action creates a protective structure that prevents the adhesive layer from contacting rollers during subsequent lamination steps.
2Productivity
If members are laminated with gaps between them, then the lamination process is faster, but the adhesive layer contacts rollers causing operational issues
Solution Approach 1:
The lamination process dynamically adjusts the overlapping configuration of members during different stages. Initially, the leading end of the second member overlaps with the first member to protect the adhesive layer. As lamination progresses, the overlapping configuration changes to accommodate the third member, maintaining protection while enabling continuous operation.
Solution Approach 2:
The lamination process maintains continuous useful action by ensuring that the adhesive layer is always protected by overlapping members throughout the entire lamination sequence. The coordinated lamination of multiple members eliminates idle time and maintains continuous protective coverage, preventing roller contact while sustaining high productivity.
3Productivity
If the third member is conveyed before the second member is fully laminated, then the lamination process is more efficient, but gaps form between members allowing adhesive contact
Solution Approach 1:
The controller coordinates the lamination process with feedback control, monitoring the lamination status and adjusting the conveyance timing of the third member accordingly. This ensures that the third member is conveyed and laminated at the optimal moment when the second member is ready, maintaining precise alignment while maximizing efficiency.
Solution Approach 2:
The controller preliminarily laminates the first member with the leading end of the second member before conveying and laminating the third member. This preliminary action establishes a stable base that maintains alignment precision while enabling efficient sequential lamination of subsequent members.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
Provided is means for reducing contact of an adhesive layer of a member, which is to be laminated, with a component in a laminating unit. A laminating device 1 includes a laminating unit 50 configured to overlap and laminate a plurality of members, a conveying unit 20 configured to convey the plurality of members to the laminating unit 50, and a controller 90. The controller 90 is configured to cause the laminating unit 50 to execute lamination in a state where a first member 101, a portion of a second member 102 including a tailing end 122 of the second member 102, and a portion of a third member 103 including a leading end 123 of the third member 103 overlap.