Layer Transfer Device Film Waste Reduction via Controller
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Solution Overview
Problem
Existing layer transfer devices waste multilayer film when the heating roller and pressure roller start rotating before the sheet is conveyed, leading to unnecessary film conveyance and waste.
Innovation Solution
A layer transfer device with a releasable restraining device that switches between a restraining state and a release state based on the presence of an image area on the sheet, ensuring the multilayer film is only conveyed when the sheet is present at the transfer position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heating roller and pressure roller start rotating before the sheet is conveyed, then the layer transfer process can be initiated early, but the multilayer film is uselessly conveyed and wasted
Solution Approach 1:
The controller performs preliminary determination of sheet presence at the transfer position before allowing the heating roller and pressure roller to rotate. This preliminary check prevents the film from being conveyed uselessly by ensuring the sheet is actually present before initiating the transfer process.
Solution Approach 2:
The system continuously monitors the transfer position to detect when a sheet is present. This feedback mechanism allows the controller to adjust the rotation timing of the heating roller and pressure roller accordingly, preventing film waste while maintaining efficient layer transfer operations.
2Manufacturing precision
If the heating roller and pressure roller rotate after receiving a layer transfer instruction, then the transfer process can be controlled precisely, but the film may be conveyed uselessly if the sheet is not properly positioned
Solution Approach 1:
The controller determines in advance whether a sheet is present at the transfer position before allowing the heating roller and pressure roller to rotate. This preliminary determination ensures precise transfer operations only occur when the sheet is properly positioned, preventing film waste.
Solution Approach 2:
The system automatically monitors its own state at the transfer position and makes decisions about when to rotate the rollers based on this self-detection. This self-service mechanism ensures precise timing without requiring external intervention, balancing accuracy with film conservation.
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 effectively reduces film waste by ensuring the multilayer film is only conveyed when the sheet is properly aligned, optimizing the layer transfer process.
Implementation Method 1
The heating roller is configured to heat the multilayer film and the sheet
Implementation Method 2
the sheet and the multilayer film are nipped between the heating roller and the pressure roller which are being rotated, and are heated by the heating roller while being conveyed through between the heating roller and the pressure roller
Implementation Method 3
The pressure roller is configured to be rotatable to convey the multilayer film and the sheet nipped between the pressure roller and the heating roller
Data Source
AI summary
A layer transfer device includes a supply reel, a take-up reel, a driving source, a releasable restraining device, a heating roller, a pressure roller, and a controller. The driving source drives the take-up reel. The releasable restraining device is capable of switching to a restraining state in which a multilayer film is put under restraint in being drawn out from the supply reel and to a release state in which the restraint is lifted. The controller is configured such that when the driving source is generating the mechanical power, the releasable restraining device is in the restraining state if an image area in which an image is formed on the sheet is not present in a layer transfer position between the heating roller and the pressure roller, and the releasable restraining device is in the release state if the image area is present in the layer transfer position.