Nip Roller With Internal Energy Source For Simultaneous Lamination And Curing
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Solution Overview
Problem
Existing pressing machines lack the capability to directly apply energy to materials during the pressing operation, which limits the efficiency of the curing process for adhesives on substrates.
Innovation Solution
A pressing machine equipped with a nip roller that has an energy source, such as a radiation-transparent material and an ultraviolet radiation source, heating element, or laser source, disposed within its inner volume, allowing for simultaneous energy application to the adhesive during the pressing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional pressing machine without internal energy source is used, then the structure is simple and easy to manufacture, but the curing process of adhesive is inefficient and time-consuming
Solution Approach 1:
The patent combines the pressing function and energy application function into a single integrated nip roller. The energy source (UV lamp, infrared heater, or microwave generator) is embedded within the nip roller itself, allowing simultaneous pressing and curing of the adhesive during the lamination process, thereby eliminating the need for separate curing equipment and improving production efficiency
Solution Approach 2:
The nip roller is designed to perform multiple functions: it applies mechanical pressure for lamination, transmits energy for adhesive curing, and can be made from different materials (radiation-transparent, heat-conductive, or microwave-absorbing) to accommodate different energy sources. This multi-functional design improves curing efficiency without proportionally increasing device complexity
2Productivity
If high energy is applied to cure adhesive quickly, then the curing speed increases, but the nip roller and surrounding components may be damaged by excessive heat or radiation
Solution Approach 1:
The nip roller is constructed with materials having specific local properties: radiation-transparent materials (glass, quartz, polycarbonate) allow UV radiation to pass through to cure adhesive; heat-conductive materials (metal cores) distribute and dissipate heat away from sensitive components; microwave-absorbing materials convert microwave energy to heat for curing. This localized material selection enables high energy application while protecting the roller and components from damage
Solution Approach 2:
The nip roller acts as an intermediary between the energy source and the adhesive. It transmits, converts, or distributes energy in a controlled manner, preventing direct exposure of sensitive components to high levels of radiation or heat while ensuring sufficient energy reaches the adhesive for effective curing
3Use of energy by moving object
If radiation-transparent material is used for the nip roller to allow energy passage, then the energy transmission efficiency is high, but the mechanical strength and durability of the roller may be reduced
Solution Approach 1:
The nip roller employs composite material construction, combining radiation-transparent materials (glass, quartz, polycarbonate) with structurally strong materials (metal cores, reinforcement layers). This composite design allows the roller to transmit radiation efficiently for curing while the reinforcing materials provide the necessary mechanical strength and durability to withstand pressing operations
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 solution enables efficient curing of adhesives on substrates, ensuring strong adhesion between the substrate and the pressed layer material, while also incorporating a cooling mechanism to manage heat and prevent damage to the nip roller and components.
Implementation Method 1
at least a portion of the at least one nip roller being constructed from a material to enable passage of energy, the at least one nip roller having an inner volume. The pressing machine also includes at least one energy source to generate energy directed at the curable adhesive to cause a curing process of the adhesive to occur
Implementation Method 2
an ultraviolet radiation source, a lamp to generate incoherent optical radiation, an electron beam radiation source, a laser source, and/or a heating element
Implementation Method 3
while also incorporating a cooling mechanism to manage heat and prevent damage to the nip roller and components
Data Source
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AI summary
Disclosed are nip rollers, machines, systems, and methods, including a nip roller that includes a hollow roller to press materials, at least a portion of the hollow roller being constructed from a material configured to enable passage of energy, and at least one energy source disposed within an inner volume of the hollow roller to generate energy, at least some of the energy being directed through the at least the portion of the hollow roller constructed from the material configured to enable passage of energy to cause curing process for a curable adhesive, deposited on a substrate and pressed against a layer material, to occur.