Lamination Gas Distribution Device with Rotating Width Control
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Solution Overview
Problem
Existing lamination systems face issues with ozone distribution that can cause corrosion and respiratory damage, and the need to adapt ozone distribution based on varying packaging material widths, especially in systems producing laminated packaging materials of different widths.
Innovation Solution
A gas distribution device with an outer and inner tube system, where the inner tube rotates relative to the outer tube to regulate the width of the gas curtain, allowing precise control of ozone application based on the width of the packaging material, ensuring ozone is only applied where needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ozone is distributed across the full width of the lamination system to ensure complete coverage, then bonding strength is improved, but corrosion and respiratory damage risks increase
Solution Approach 1:
The gas distribution device delivers ozone selectively only to the areas where laminated packaging material is actually produced, rather than distributing ozone across the entire width of the lamination system. This localized approach ensures sufficient ozone concentration for bonding activation while minimizing unnecessary ozone exposure that causes corrosion and respiratory damage.
Solution Approach 2:
The gas distribution device can dynamically adjust the transverse gas flow distribution according to the current production width of the laminated packaging material. This dynamic adaptation allows the system to optimize ozone distribution in real-time, ensuring complete coverage only where material is present while reducing ozone exposure in unused areas.
2Adaptability or versatility
If the lamination system is configured to produce different widths of laminated packaging material, then versatility is improved, but ozone distribution control becomes more difficult
Solution Approach 1:
The gas distribution device incorporates adjustable gas flow control means that can modify the transverse gas flow distribution according to the selected production width. This dynamic control capability allows the system to adapt to different material widths while maintaining precise ozone distribution, avoiding the need for multiple fixed configurations.
Solution Approach 2:
The gas distribution device serves multiple functions: it distributes ozone across varying widths, controls flow distribution patterns, and adapts to different production configurations. This multi-functionality is achieved through the combination of the distribution device with adjustable flow control means, eliminating the need for separate systems for each width configuration.
3Quantity of substance
If ozone is distributed beyond the actual material width to ensure complete coverage, then bonding coverage is improved, but waste and exposure risks increase
Solution Approach 1:
The system concentrates ozone distribution precisely where laminated packaging material is present by using adjustable gas flow control means. This ensures that ozone is delivered only to the necessary areas for bonding activation, preventing ozone waste in regions where no material is being processed while maintaining complete coverage where needed.
Solution Approach 2:
The gas distribution device can adjust its transverse flow distribution based on feedback regarding the actual material width and position. This feedback mechanism ensures that ozone distribution automatically adapts to the current production conditions, optimizing coverage while minimizing waste and unnecessary exposure.
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 prolongs the lifetime of the lamination system by preventing direct ozone exposure to unnecessary areas, while ensuring strong bonding between thermoplastic and other layers, and allows production of laminated packaging materials of varying widths.
Implementation Method 1
ozone can be used to activate and/or generate bonding seats or sites in the surface of the thermoplastic film
Implementation Method 2
The inner tube comprising a plurality of regulation holes distributed along the longitudinal extension. Each regulation hole has a different elongation in a direction perpendicular to the longitudinal extension. An elongation of the regulation holes is increasing as seen from an outer end of the first end portion of the outer tube. The plurality of regulation holes overlap with at least a subset of the plurality of gas distribution holes.
Data Source
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AI summary
The present invention relates to a lamination system configured to produce a laminated packaging material. The lamination system comprising: an impression roller and a counter roller together forming a press nip; and an extruder. The lamination system is configured to feed a web of a core material layer into the press nip. The extruder is configured to provide a film of thermoplastic onto the web of core material layer as facing one of the impression roller or the counter roller. The lamination system further comprising a gas distribution device configured to distribute a flow of gas onto a surface of the film before the film enters the press nip. The gas distribution device comprising: an outer tube having a longitudinal extension and having a plurality of gas distribution holes distributed along the longitudinal extension; and an inner tube being rotationally arranged within the outer tube at a first end portion of the outer tube. The inner tube comprising a plurality of regulation holes distributed along the longitudinal extension. Each regulation hole has a different elongation in a direction perpendicular to the longitudinal extension, wherein an elongation of the regulation holes is increasing as seen from an outer end of the first end portion of the outer tube. The plurality of regulation holes overlap with at least a subset of the plurality of gas distribution holes.