Modular Spacer Frame for Diaphragm Press Adaptation
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Solution Overview
Problem
Existing membrane presses for multi-sided coating of three-dimensionally curved flat workpieces require stable and heavy spacer frames to handle high forces, making them difficult to adapt, expensive, and risky to convert, especially for varying workpiece sizes.
Innovation Solution
A modular spacer frame design with an exchangeable inner valley frame and a press-resistant outer pressure frame, allowing for easy adjustment and reduced weight, enabling manual handling and minimizing injury risk, with individual frames composed of light metal profiles and sliding elements for friction reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid and heavy spacer frame is used to absorb high forces, then the stability and strength are improved, but the adaptability and ease of handling deteriorate
Solution Approach 1:
The spacer frame is divided into a modular system consisting of a reusable outer pressure frame and exchangeable inner valley frames. The outer pressure frame absorbs the high pressing forces, while the lighter inner valley frames can be easily exchanged to adapt to different workpiece heights, resolving the contradiction between strength and adaptability
Solution Approach 2:
The function of force absorption is extracted and assigned to the outer pressure frame, which remains solid and heavy. The inner valley frame is extracted from the force-bearing function and can be made lightweight for easy handling and exchange, allowing adaptability without compromising overall strength
2Strength
If a solid and heavy spacer frame is used to absorb high forces, then the strength is improved, but the ease of operation deteriorates
Solution Approach 1:
By segmenting the spacer frame into an outer pressure frame and inner valley frame, the heavy outer frame remains fixed to provide strength, while the lighter inner valley frames can be easily removed and exchanged by operators without requiring lifting aids, improving ease of operation
Solution Approach 2:
The exchangeable inner valley frame is extracted as a separate component that does not need to bear the full pressing forces. This allows it to be made lightweight and easy to handle, while the outer pressure frame retains the necessary strength for force absorption
3Adaptability or versatility
If multiple spacer frames with different heights are kept available, then the adaptability is improved, but the device complexity and cost increase
Solution Approach 1:
The valley frame is segmented into multiple individual frames that can be stacked vertically. By stacking different numbers of identical individual frames, various heights are achieved without needing to store multiple complete spacer frame sets, reducing device complexity and inventory requirements
Solution Approach 2:
The individual valley frames are designed as universal components that can be combined in different quantities to create valley frames of various heights. This multi-functional design allows a single type of component to serve multiple height requirements, reducing the total number of different parts needed
4Stability of the object's composition
If a heavy valley frame is used to ensure stability, then the strength is improved, but the ease of operation and safety deteriorate
Solution Approach 1:
The stability function is extracted and assigned to the outer pressure frame, which remains heavy and stable. The inner valley frame is extracted from the stability requirement and can be made lightweight for easy manual handling, eliminating the need for lifting aids and reducing injury risk while maintaining overall system stability through the outer frame
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 economic, quick, and safe adaptation to different workpiece sizes, reducing the need for multiple spacer frames and lifting aids, improving handling and flexibility, while maintaining force absorption and sealing capabilities.
Implementation Method 1
with a membrane being held below the upper press plate, which together with the upper press plate forms an upper overpressure space. Furthermore, the known device has a spacer frame resting directly or indirectly on the lower press plate with a height dimension which is adapted to the height dimension of a workpiece blank supported by a substructure, which in turn is mounted directly or indirectly on the lower press plate, with the device being in the closed state below a lower vacuum space is created in a coating film spanning the spacer frame.
Data Source
Figure 1~2
Figure 3~5
AI summary
The membrane press has a press frame (1) that consists of an upper press plate (2) and a lower press plate (3) which are moved against each other in the press frame. A diaphragm (5) is held directly or indirectly on the lower press plate below the upper press plate. The press frame supports workpieces (12,13) of the substructures (10,11) directly or indirectly on the lower press plate. The press frame having several portions and an exchangeable inner frame fillet (6,7), is arranged in an outer press frame (8).