Flexible Screen Frame Lamination With Heated Rollers and Alignment
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Solution Overview
Problem
Current manufacturing processes for flexible window screens are labor-intensive and inefficient, involving manual operations that are time-consuming and prone to inferior weld quality due to polymer coating contamination, leading to suboptimal performance during insertion and removal.
Innovation Solution
A mesh to flexible screen frame laminator system comprising an entry table, processing table, and exit table, equipped with heater rollers and shrink tube heaters, automates the fusion of mesh to flexible frames using adjustable heater rollers and fences to maintain alignment and ensure polymer coating uniformity, facilitating the process, ensuring polymer coating uniformity, and the application of heat to the polymer coating of the screen frame material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes are used for manufacturing flexible window screens, then labor flexibility is maintained, but production efficiency is low and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical operations with an automated heating and fusing system. The apparatus uses heated rollers and controlled thermal processes to automatically fuse mesh to flexible frames, eliminating manual labor while maintaining precise control over the manufacturing process.
Solution Approach 2:
The invention controls and optimizes thermal parameters (temperature, heating time, pressure) during the fusing process. By precisely adjusting these parameters, the system achieves efficient automated production while ensuring consistent weld quality and adhesion strength between mesh and frame materials.
2Reliability
If resistance welding is used to join frame ends, then structural integrity is achieved, but polymer coating contamination causes inferior weld quality
Solution Approach 1:
The patent applies heat to the polymer coating of the flexible frame material during the fusing process, which pre-treats the surface by partially melting or softening the polymer. This preliminary thermal action prepares the surface for better adhesion and prevents contamination issues that would otherwise occur during subsequent welding or fusing operations.
Solution Approach 2:
The invention works with composite materials consisting of metal frames coated with polymer materials. By understanding and utilizing the properties of this composite structure, the process selectively heats and treats the polymer coating to achieve proper adhesion without compromising the underlying metal frame or introducing contamination.
3Ease of operation
If flexible screen frames are deformed for insertion, then ease of installation is achieved, but excessive force may damage the resilient structure
Solution Approach 1:
The patent designs the flexible frame with inherent dynamic properties, allowing it to deform elastically during insertion and then spring back to its original shape. The resilient steel construction enables controlled deformation and recovery, facilitating easy installation while maintaining structural integrity and preventing permanent damage.
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 system enhances production efficiency by automating the fusion process, reducing manual labor, and improving weld quality by ensuring consistent adhesion of the mesh to the frame, thereby enhancing the flexibility and durability of the screens.
Implementation Method 1
The shrink tube heater is structured to retract below the horizontal supporting surface and also to extend above the horizontal supporting surface... application of heat to the polymer coating of the screen frame material
Implementation Method 2
processing table, and exit table, equipped with heater rollers and shrink tube heaters, automates the fusion of mesh to flexible frames using adjustable heater rollers... application of heat to the polymer coating of the screen frame material
Implementation Method 3
the screen mesh is fused to the flexible screen frame by the application of heat which renders the polymer material of the screen frame, the screen mesh or both at least partially molten during the manufacturing of the screen
Implementation Method 4
the flexible screen frame is generally resiliently biased outwardly toward an approximately rectangular shape... Deformation of the flexible screen frame is generally accomplished by pressing inwardly on two opposing straight sides of the screen frame
Data Source
AI summary
A mesh to flexible screen frame laminator includes a first table with a horizontal surface and an alignment fence, a second table that is lower than the first table and a first pair of selectively driven heater rollers which are shiftable between a raised position and a lowered position relative to the first table. A cradle is located adjacent the first table and above the second table and at least a portion of the cradle is shiftable between a raised position and a lowered position, the raised position being substantially coplanar with the first table. A second pair of selectively driven heater rollers is shiftable between a raised position and a lowered position relative to the second table and is oriented transversely to the first pair of heater rollers. A third table is located adjacent the second table and at a height substantially coplanar with the second table.