Microwave Bonding Machine with Fluidized Particle Bed

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Solution Overview

Problem

Existing methods for bonding flexible coverings to supports, such as those used in upholstery, face issues with energy inefficiency, ergonomic concerns, and ineffective temperature control, particularly with the use of hot gas and microwave technologies, which lead to increased energy waste and compromised bonding quality.

Innovation Solution

A machine and method utilizing a bed of particles fluidized by a wet gas flow combined with electromagnetic waves to rapidly heat adhesive layers, allowing for precise temperature control and efficient bonding, while maintaining a safe and ergonomic working environment through the use of a conductive casing and wave stirrers to ensure uniform heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If hot gas is used to activate the adhesive, then the adhesive bonding function is achieved, but energy is wasted and the workstation temperature increases

Engineering Contradiction:

Improveadhesive temperatureVSAvoidenergy waste

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent replaces the hot gas heating system with an electromagnetic wave heating system. The electromagnetic waves directly heat the adhesive layer without requiring hot gas circulation, eliminating the energy waste associated with heating and circulating large volumes of gas while achieving the same adhesive activation temperature.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces water droplets as an intermediary medium to transfer electromagnetic energy to the adhesive. The water droplets absorb electromagnetic radiation and convert it to heat, which is then transferred to the adhesive layer, providing efficient and localized heating without the need for hot gas.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If microwaves are used to heat the adhesive, then heating speed is improved, but temperature control becomes difficult

Engineering Contradiction:

Improvebonding speedVSAvoidtemperature control

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent applies electromagnetic waves locally to the adhesive layer through water droplets positioned at the bonding interface. This localized heating approach allows precise temperature control of the adhesive without overheating surrounding materials, enabling fast bonding with controlled temperature.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses a controlled amount of water droplets to mediate the heating process. The water droplets are sufficient to absorb electromagnetic energy and transfer it to the adhesive, but not excessive to cause damage to the bonding materials, achieving optimal temperature control for rapid bonding.

Inventive Principle:

Principle #16Partial or excessive action

3Temperature

If a perforated mould is used for microwave heating, then adhesive heating is achieved, but the mould cost increases significantly

Engineering Contradiction:

Improveadhesive temperatureVSAvoidmould cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent replaces the complex perforated mould structure with a simple electromagnetic wave emission system. The electromagnetic waves penetrate through the materials to heat the adhesive directly, eliminating the need for expensive perforated moulds while achieving the same heating effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses water droplets as an intermediary to enable microwave heating without requiring special mould structures. The water droplets absorb and convert electromagnetic energy to heat the adhesive, allowing the use of simple, non-perforated moulds and significantly reducing manufacturing costs.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach significantly reduces energy consumption, enhances bonding speed and quality, and allows for the production of complex upholstery items with multiple layers, including non-permeable materials, by rapidly activating adhesives with electromagnetic waves and cooling them quickly, resulting in substantial energy savings and improved productivity.

Implementation Method 1

at least one electromagnetic wave emitter (12) placed so that the waves are oriented in the direction of the compression member (10)

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Dielectric Heating

Implementation Method 2

a bed of particles (4) fluidised by a flow of gas, comprising a gas distributer (6)

Methodology Applied

Scientific EffectFluidization: Fluidisation

Implementation Method 3

the use of high frequency electromagnetic waves... to heat water droplets forming part of the adhesive formulation

Methodology Applied

Scientific EffectMicrowave heating: Microwave Radiation

Data Source

PatentUS11225064B2Method and machine for bonding a flexible coating to a support using electromagnetic waves and lining produced in this way

Publication Date: 2022.01.18 C GEX SYSTS

AI summary

A machine (1) and a method for thermobonding using an emission of electromagnetic waves (13), for example microwaves, to activate one or a plurality of adhesive layers located between a support and one or a plurality of layers of flexible covering, through a bed of particles (4) fluidized by a humidified gas. A multi-layer upholstery item including at least one non-permeable layer and produced in a single operation is also described.