Laminating Device with Movable Heated Plate for Even Film Bonding
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Solution Overview
Problem
Existing small laminating devices struggle to achieve robust and even lamination of thin films on thicker substrates like cardboard or hard plastic, due to inconsistent pressure and heating issues, leading to weak or absent bonding.
Innovation Solution
A laminating device with a movable heated plate and pressure roller system that allows for precise control of pressure and even heating, ensuring the hot-melt adhesive melts consistently across the surface, and includes a lever mechanism for manual operation and adjustable pressure to accommodate varying substrate thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed-distance rollers are used for lamination, then the device structure is simple, but the pressure varies with substrate thickness leading to poor lamination quality
Solution Approach 1:
The invention replaces fixed-distance rollers with a movable plate that can adjust its position vertically. The plate is movable relative to the base, allowing the lamination pressure to adapt to different substrate thicknesses. This dynamic adjustment capability ensures consistent lamination quality across varying material thicknesses while maintaining a relatively simple device structure.
2Device complexity
If conventional roller heating is used, then the heating structure is simple, but the temperature distribution is uneven causing insufficient adhesive melting
Solution Approach 1:
The heating system is segmented into multiple independent heating zones along the plate. Each zone can be controlled independently to ensure uniform temperature distribution across the entire lamination surface. This segmentation allows precise thermal management, preventing hot spots and ensuring consistent adhesive melting throughout the substrate.
3Use of energy by moving object
If the plate heating speed is slow, then energy consumption is low, but the lamination process time increases
Solution Approach 1:
The plate is preheated to the required temperature before the lamination process begins. This preliminary heating action ensures that when the substrate passes through, the adhesive melts immediately and uniformly, significantly reducing the actual lamination time. The thermostat controls the preheating process to maintain optimal temperature, balancing energy consumption with processing speed.
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 high-quality lamination of thin films on thicker substrates with a finish comparable to industrial devices, ensuring robust bonding and minimizing thermal damage, while being cost-effective and suitable for home or small office use.
Implementation Method 1
a heating element for heating the plate and/or the base to a temperature that is above the melting temperature of the hot-melt adhesive
Implementation Method 2
the hot-melt adhesive melts
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Laminating device for affixing a film (41) on a substrate (42) whereby the film (41) and/or the substrate (42) are provided with a coat of hot-melt adhesive, characterised in that the laminating device (1) is provided with: • a base (3) and a plate (8) that is movable vertically with respect to the base (2) and which together with the base (2) forms a space (9) in which the substrate (42), together with the film (41) to be laminated affixed against it, can be introduced; • means to lift the plate (8) upwards and lower it again to a rest position in which the plate (8) can rest on a substrate (42) with a film (41) to be laminated that is in the space between the plate (8) and the base (3); • a heating element (25) for heating the plate (8) and/or the base (3) to a temperature that is above the melting temperature of the hot-melt adhesive; and • an input and output (34) for the entry and exit of the substrate (42) together with the film (41) to be laminated to and from the space (9) between the base (3) and the plate (8).