Layered Sheet Manufacturing Device Thickness Deviation Protection
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Solution Overview
Problem
In the manufacturing of layered sheets, changes in thickness or the presence of foreign substances can cause high loads on energy applying devices, leading to adverse effects such as breakage.
Innovation Solution
A layered sheet manufacturing device with an anvil roll, energy applying device, nip stage, detection device, and retreat mechanism that detects thickness deviations and moves the energy applying device away from the anvil roll to prevent adverse effects, using a displacement member and lever-sensor system to amplify thickness deviations for detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the energy applying device maintains constant contact with the layered body, then continuous manufacturing is efficient, but thickness variations cause high loads and device breakage
Solution Approach 1:
The energy applying device is made movable in the thickness direction through a retreat mechanism, allowing it to dynamically adjust its position based on detected thickness variations. This resolves the contradiction by enabling the device to retreat when thickness deviations are detected, preventing high loads and breakage, while maintaining contact during normal operation for continuous efficient manufacturing.
Solution Approach 2:
A detection device monitors the thickness of the layered body in real-time and provides feedback to control the retreat mechanism. When thickness variations exceeding a predetermined range are detected, the feedback system activates the retreat mechanism to move the energy applying device away, preventing adverse effects. This feedback loop resolves the contradiction by automatically adjusting device position based on actual thickness conditions.
2Reliability
If the space between anvil roll and energy applying device is increased to prevent damage, then device reliability improves, but manufacturing efficiency decreases
Solution Approach 1:
Rather than maintaining a permanently increased space, the energy applying device dynamically adjusts its position - maintaining normal contact for efficient manufacturing, then retreating only when thickness deviations are detected. This resolves the contradiction by providing device protection only when needed, without continuously reducing manufacturing efficiency.
Solution Approach 2:
The retreat mechanism operates periodically or intermittently based on detection device input, retreating only when thickness variations are detected and returning to normal position afterward. This resolves the contradiction by minimizing the time the device is retreated, thus maintaining high manufacturing efficiency while providing protection when necessary.
3Reliability
If thickness detection is implemented upstream, then adverse effects are prevented, but device complexity increases
Solution Approach 1:
A detection device is introduced as an intermediary component upstream of the energy applying device to monitor thickness variations. This intermediary detects thickness deviations and triggers the retreat mechanism, preventing adverse effects. While this adds a component, it uses a relatively simple sensing and control system that manages complexity while providing reliable protection.
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
Prevents adverse effects on the energy applying device by increasing the space between the anvil roll and energy applying device before thickness deviations reach the energy applying device, ensuring continuous operation and preventing damage.
Implementation Method 1
a displacement member that amplifies a dimensional change; and a detection device that detects whether a thickness of the layered body has deviated from a predetermined reference range or not on the basis of the displacement member
Implementation Method 2
an energy applying device that applies an energy for thermally fusing layers of the layered body together
Implementation Method 3
an energy applying device that applies an energy for thermally fusing layers of the layered body together
Data Source
AI summary
A layered body containing continuous sheets is thermally fused when passing through a space between an anvil roll and an energy applying device to form a layered sheet. A nip stage for sandwiching the layered body is provided upstream of the space between the anvil roll and the energy applying device. The nip stage includes at least one displacement member which is displaced in accordance with the thickness of the layered body sandwiched by the nip stage. Whether the thickness of the layered body sandwiched by the nip stage has deviated from a reference range is detected on the basis of the displacement of the displacement member, and when it is detected that the thickness has deviated from the reference range, the energy applying device is caused to retreat in a direction going away from the anvil roll.