Roll Coater Temperature and Humidity Control for Thermosetting Adhesives
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Solution Overview
Problem
Thermosetting adhesives with high viscosity (1000 mPa·s to 2500 mPa·s) tend to increase in viscosity when application operations are temporarily stopped, leading to unstable application and waste due to accelerated reaction with moisture, necessitating frequent cleaning of rollers.
Innovation Solution
An adhesive application device with a coater and air conditioning system that includes a roll temperature control and air conditioning device to maintain appropriate adhesive viscosity and humidity levels, using a roll coater with temperature-controlled rolls and an air conditioning device to adjust ambient conditions, preventing viscosity increase and condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the roller is kept rotating during temporary production stops to prevent adhesive curing, then the adhesive can be applied stably after resuming, but the heat from the roller accelerates the reaction with moisture and increases viscosity excessively
Solution Approach 1:
The roller temperature is dynamically adjusted based on production status. During temporary stops, the roller temperature is reduced to prevent excessive viscosity increase, while during active production, the roller is heated to maintain application stability. This dynamic temperature control resolves the contradiction between maintaining application stability and preventing excessive heat-induced viscosity increase.
Solution Approach 2:
The invention changes the temperature parameter of the roller based on operational conditions. By adjusting the heating temperature or introducing cooling mechanisms, the system adapts the roller temperature to match the production state, preventing the harmful effect of excessive heat while maintaining the necessary thermal conditions for stable adhesive application during active production.
2Ease of operation
If the roller temperature is increased to maintain adhesive flow during production, then the adhesive applies smoothly, but the viscosity increases excessively during temporary stops due to accelerated reaction with moisture
Solution Approach 1:
The system dynamically adjusts roller temperature based on production status. During active production, the roller is heated to ensure smooth adhesive application. During temporary stops, the heating is reduced or cooling is applied to prevent excessive viscosity increase, allowing the system to maintain ease of operation during production while minimizing time loss during stops by preventing adhesive waste.
Solution Approach 2:
The invention converts the potential harm of roller heat (which accelerates moisture reaction and increases viscosity) into a benefit by controlling when the heat is applied. The roller heating is activated only during active production when it benefits application smoothness, and deactivated or cooled during stops when it would cause harmful viscosity increase, thus turning a potentially harmful effect into a controlled beneficial one.
3Strength
If high viscosity thermosetting adhesive is used, then the adhesive provides good bonding properties, but the viscosity increases excessively during temporary stops requiring frequent roller cleaning
Solution Approach 1:
The invention changes the temperature parameter of the roller to control adhesive viscosity during temporary stops. By reducing or eliminating heating during stops, the system prevents the excessive viscosity increase that would otherwise occur, maintaining both the bonding strength properties of the high viscosity adhesive during production and the production efficiency by eliminating frequent cleaning requirements.
Solution Approach 2:
The roller temperature control is made dynamic, adjusting to production status. During active production, the roller maintains temperature for proper adhesive flow and bonding. During temporary stops, the temperature is reduced to prevent viscosity increase, thereby maintaining productivity by avoiding frequent cleaning interruptions while preserving the bonding strength characteristics of the high viscosity adhesive.
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
The device stabilizes adhesive application by controlling viscosity and humidity, preventing excessive increase even during temporary stops, ensuring consistent application without waste and roller cleaning.
Implementation Method 1
The roll temperature control device is disposed adjacent to the first roll and configured to lower temperature of the outer surface of the first roll to control viscosity of the thermosetting adhesive held by the first roll
Implementation Method 2
The air conditioning device is configured to adjust temperature and humidity of air in a space near the coater
Implementation Method 3
The air conditioning device is configured to adjust temperature and humidity of air in a space near the coater
Data Source
AI summary
An adhesive application device includes a coater and an air conditioning device. The coater includes a roll and a roll temperature control device. The roll has an elongated shape having an axis and outer surface and is rotatable around the axis. The roll holds thermosetting adhesive on the outer surface and applies the thermosetting adhesive to an application surface of a sheet member with the first roll being rotated and contacted with the sheet member. The roll temperature control device is disposed adjacent to the roll and configured to lower temperature of the outer surface of the roll to control viscosity of the thermosetting adhesive held by the roll to be appropriate application viscosity that is appropriate for application to the sheet member. The air conditioning device is configured to adjust temperature and humidity of air in a space near the coater.