Lamination Apparatus Using Gravure Coating for Fast-Curing Adhesive
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Solution Overview
Problem
Existing lamination apparatuses face issues with positional deviation due to slow curing of adhesives and liquid sagging during application, particularly when using two-component curable adhesives with low viscosity.
Innovation Solution
A lamination apparatus and method that employs a first coating unit with a roll coater for a main agent and a second coating unit with a gravure coating machine for a curing agent, controlling temperature and viscosity to ensure fast curing and prevent liquid sagging, with a coating weight ratio between 1:1 to 10:1 and viscosity between 10 mPa·S and 500 mPa·S.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a two-component curable adhesive mixture is stored in a reservoir and applied by a roll coater, then the adhesive can be applied to the web, but the curing of the adhesive mixture must be slowed down to increase pot life, which causes positional deviation after bonding
Solution Approach 1:
The adhesive system is segmented into two separate components (main agent and curing agent) that are applied to different webs by different coating units. The main agent is applied by a roll coater to the first web, while the curing agent is applied by a gravure coating machine to the second web. This segmentation allows each component to be optimized independently for its application method and prevents premature curing while maintaining bonding precision.
Solution Approach 2:
The invention introduces an intermediary approach where the two adhesive components are kept separate until the bonding stage. The main agent and curing agent act as intermediaries that only combine and initiate curing when the webs are bonded together. This intermediary separation resolves the contradiction by preventing premature curing (extending pot life) while ensuring precise bonding when the components finally mix.
2Speed
If a low viscosity coating liquid is used, then the adhesive cures faster, but liquid sagging occurs during application which degrades coating quality
Solution Approach 1:
The coating process is segmented into two separate coating units, each optimized for different viscosity requirements. The roll coater applies the main agent (which can have higher viscosity), while the gravure coating machine applies the curing agent (which can have lower viscosity for faster curing). This segmentation allows low-viscosity adhesive to be used without liquid sagging because the gravure machine is specifically designed to handle and precisely apply low-viscosity materials.
Solution Approach 2:
The invention changes the parameter of viscosity control by separating the adhesive into two components with different viscosity characteristics. The curing agent can be formulated with lower viscosity to enable faster curing, while the main agent can have higher viscosity to prevent sagging during its application phase. This parameter change resolves the contradiction between curing speed and coating quality.
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 the use of fast-curing adhesives, reduces positional deviation, and improves coating quality by preventing liquid sagging, while allowing for stable application of low-viscosity coatings.
Implementation Method 1
application of one coating liquid selected from the main agent and the curing agent through gravure printing can prevent liquid sagging and improve coating quality
Implementation Method 2
a temperature controller that controls the temperature of the coating liquid stored in the coating liquid tank
Implementation Method 3
an adhesive starts to cure when the webs are bonded together
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
[Object] Provided are a lamination apparatus and a lamination method in which a fast-curing adhesive can be used and which can improve the quality of a composite film and enables application of a low-viscosity coating liquid. [Solution] A lamination apparatus 1 includes a first coating unit 12 that applies, as a coating liquid, one of a main agent and a curing agent of a two-component curable adhesive to a first web W1; a second coating unit 14 that applies, as a coating liquid, the other one of the main agent and the curing agent of the two-component curable adhesive to a second web W2, the other one being the one not applied to the first web W1; and a bonding unit 151 that bonds a coating liquid-applied surface of the first web W1 and a coating liquid-applied surface of the second web together. The second coating unit 14 is a gravure coating machine.