Nonwoven Molding Press Lamination With Spacer-Controlled Pressure
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Solution Overview
Problem
The existing methods for thermoforming and laminating semi-finished nonwoven fabrics require multiple devices and apply high stress to the decoration, leading to uneven or damaged surfaces in the final product, making them time-consuming and energy-intensive.
Innovation Solution
A modified method using a moulding press with a spacer between the upper and lower tools, where the decoration is coated with a reactive hot melt adhesive, and the process involves thermoforming at 190-230°C, cooling to 150-180°C, applying the decoration, and closing the press with a spacer to reduce pressure and achieve lamination in one device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a moulding press is employed without modification in the lamination step, then the lamination can be performed in the same device, but a high stress on the surface of the decoration is applied which leads to an uneven or even damaged surface of the decoration in the final product
Solution Approach 1:
The patent applies dynamics by making the moulding press adaptable to different operational modes through the introduction of a spacer element. The spacer can be inserted or removed to modify the pressing characteristics, allowing the same device to perform both high-pressure thermoforming and low-pressure lamination operations, thus resolving the contradiction between device simplicity and product quality
Solution Approach 2:
The patent changes the pressure parameter by introducing a spacer that limits the closing force of the moulding press during lamination. This parameter modification allows the decoration surface to be bonded without excessive stress, preventing surface damage while maintaining the benefits of using a single device
2Manufacturing precision
If traditional methods are used with multiple devices, then the lamination can be performed with controlled pressure, but the process is time-consuming and requires more energy
Solution Approach 1:
The patent merges the thermoforming and lamination operations into a single integrated process using one moulding press. By combining these operations and using the spacer to control pressure, the method achieves both high surface quality and improved productivity, eliminating the need for separate devices and reducing manufacturing time
3Manufacturing precision
If traditional methods are used with multiple devices, then the lamination can be performed with controlled pressure, but more energy is needed to operate multiple devices
Solution Approach 1:
The patent merges multiple energy-consuming devices into a single moulding press operation. By using the spacer to enable controlled low-pressure lamination within the same device used for thermoforming, the method reduces total energy consumption while maintaining decorative surface quality
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 method reduces the number of machines needed, decreases energy consumption, and ensures a shorter process while maintaining excellent surface quality by applying lower pressure and temperature, resulting in a laminated nonwoven moulded article with improved surface integrity.
Implementation Method 1
the decoration (6) coated with a reactive hot melt adhesive having a melting temperature ranging from 105-134° Celsius
Implementation Method 2
applying a decoration upon the nonwoven moulded article, the decoration (6) coated with a reactive hot melt adhesive
Implementation Method 3
a spacer is used between the upper and the lower tools of the moulding press and whereby the surface of the decoration, which is bonded to the nonwoven moulded article, is coated with a reactive hot melt adhesive
Implementation Method 4
the thermoforming is performed at 190 to 220°C in a moulding press by steam
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention pertains to a method for thermoforming and laminating a semi-finished nonwoven fabric in a moulding press, the article obtained therefrom, and a device for thermoforming and laminating a semi-finished nonwoven fabric. The method comprises thermoforming a semi-finished nonwoven fabric in a moulding press to obtain a nonwoven moulded article; opening the moulding press and inserting at least one spacer between the upper tool and lower tool of the moulding press; subsequently applying a decoration upon the nonwoven moulded article; closing the moulding press for 2 to 300 seconds to obtain a laminated nonwoven moulded article; and removing the spacer and the obtained laminated nonwoven moulded article. The surface of the decoration, which is bonded to the nonwoven moulded article, is coated with a reactive hot melt adhesive.