Laminator Heating Arrangement with Reflector and Thermal Connector
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Solution Overview
Problem
Conventional laminating machines take a long time to reach working temperature, and existing infrared heating methods are difficult to control, risking overheating of rollers and damage to the silicone coating.
Innovation Solution
A laminating device with a radiating element, reflector, and thermal connector, where the thermal connector's temperature matches the roller's surface temperature, allowing for controlled heating and cooling, preventing overheating, and ensuring the roller reaches optimal temperature quickly and safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resistance heating through aluminum shoes is used, then the rollers are heated effectively, but the heating time is too long (5-7 minutes)
Solution Approach 1:
The patent replaces the conventional mechanical resistance heating system (aluminum shoes with electrical heating elements) with an optical heating system using infrared radiating elements. This substitution allows for much faster heating of the roller surfaces, reducing the warm-up time from 5-7 minutes to approximately 1 minute while maintaining effective heating capability.
Solution Approach 2:
The patent implements periodic heating cycles where the infrared radiating elements are activated only when the roller temperature falls below the optimal laminating temperature range. This periodic action maintains the roller temperature within the desired range (90°C to 110°C) without requiring continuous heating, thus reducing overall heating time and energy consumption while preventing overheating.
2Loss of time
If infrared radiation heating is used, then the roller surface is heated quickly, but the heating is difficult to control and may cause overheating
Solution Approach 1:
The patent incorporates temperature sensors that continuously monitor the roller surface temperature and provide feedback to the control system. Based on this feedback, the controller adjusts the operation of infrared radiating elements and reflectors to maintain the roller temperature within the optimal range (90°C to 110°C). This feedback mechanism enables precise control of the rapid infrared heating process, preventing both underheating and overheating.
Solution Approach 2:
The patent employs dynamic control of the infrared heating system, where the operation of radiating elements and reflectors is continuously adjusted based on real-time temperature conditions. The system transitions between different operational states (heating, maintaining, cooling) to adapt to changing temperature conditions, ensuring optimal control throughout the heating process.
3Productivity
If the roller temperature is raised quickly to improve productivity, then the operational efficiency increases, but the silicone coating may be permanently damaged
Solution Approach 1:
The patent performs preliminary heating of the roller surface using infrared radiation to rapidly reach the optimal temperature range (90°C to 110°C) before laminating operations begin. This preliminary action ensures the roller is fully prepared for efficient operation while the control system is already in place to prevent excessive temperature rise that could damage the silicone coating.
Solution Approach 2:
The patent carefully controls the temperature parameter within a specific optimal range (90°C to 110°C) rather than using excessively high temperatures. By maintaining the temperature within this controlled range and implementing automatic temperature regulation, the system achieves high productivity while preventing thermal damage to the silicone coating, which would occur at temperatures significantly above this range.
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
The device is ready for use within minutes, with controlled heating and cooling mechanisms ensuring the roller operates within a safe temperature range, extending the lifespan of the silicone coating and improving operational efficiency.
Implementation Method 1
heating of each roller is achieved by providing a relatively heavy aluminum shoe, which has a curved inner surface lying close to a region of the roller. When the laminating device is switched on, the shoe is heated, usually by resistance heating, and heat energy is transferred from the shoe to the roller by radiation and convection.
Implementation Method 2
a reflector, having a main body, and being configured and positioned so that energy radiated from the radiating element is reflected and concentrated so as to exit the reflector in a direction towards the laminating roller
Implementation Method 3
a thermal connector, having first and second ends, the first end being in thermal contact with the main body, the arrangement being such that when the radiating element is switched on, and the temperature of the second end of the thermal connector and the temperature of the surface of the laminating roller are approximately equal and below an optimal laminating temperature, the temperature of the second end of the thermal connector rises at substantially the same rate as the surface of the laminating roller
Data Source
AI summary
A laminating arrangement includes a laminating roller and a radiating element to radiate energy therefrom. A reflector has a main body and is configured so that energy radiated from the radiating element is reflected and concentrated to exit the reflector in a direction towards the laminating roller. A thermal connector has first and second ends, the first end being in thermal contact with the main body of the reflector. When the radiating element is switched on, and the temperature of the second end of the thermal connector and the temperature of the surface of the laminating roller are approximately equal and below an optimal laminating temperature, the temperature of the second end of the thermal connector rises at substantially the same rate as the surface of the laminating roller. A thermometer is positioned to measure the temperature of the thermal connector at or near the second end.