Self-Threading Lamination Head for Faster Material Roll Changeouts
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Solution Overview
Problem
Conventional lamination heads require time-consuming manual threading of layup material, leading to significant downtime during material roll changeouts, which increases production flow time.
Innovation Solution
A lamination head with self-threading capability, featuring a material supply drum, a material threading system with a continuous-loop threading belt and belt-mounted layer engagement device, and a backing layer collection drum, autonomously threads the backing layer through the lamination head, reducing downtime by automating the material roll change process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual threading of layup material is used in conventional lamination heads, then the material roll changeout process is simple and reliable, but significant downtime occurs during threading operations, increasing production flow time
Solution Approach 1:
The lamination head performs threading operations autonomously without requiring external manual intervention. The threading system automatically guides the layup material through the lamination head components, and the collection drum automatically winds the backing layer, enabling the system to service itself during material roll changeouts.
Solution Approach 2:
The threading system is pre-configured with guide components and the collection drum is pre-positioned to receive the backing layer. Before the material roll is fully depleted, the threading process can be initiated, and the system is prepared in advance to seamlessly transition to the next material roll without interruption to the main lamination process.
2Productivity
If automated threading system is implemented, then production efficiency is enhanced and manual intervention is reduced, but device complexity increases due to additional threading components
Solution Approach 1:
The collection drum serves multiple functions: it collects and winds the backing layer during normal operation, and it also acts as an active component in the threading process by automatically winding the backing layer as the material is threaded through the system. This multi-functionality reduces the need for separate dedicated threading components.
Solution Approach 2:
The threading system is integrated with the existing lamination head structure and the collection drum mechanism. The threading belt and guide components are combined with the material delivery system, and the backing layer winding function is merged with the collection drum's normal operation, thereby reducing overall system complexity despite adding automation capability.
Data Source
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AI summary
A self-threading lamination head (200) has a material supply drum (220), a backing layer collection drum (300), and a material threading system. The material supply drum (220) supports a material roll (224) of backed material (226), comprising layup material (228) backed by a backing layer (230). The material threading system includes at least one threading belt (326) located on one side of the lamination head (200). The threading belt (326) is supported by belt rollers (328) driven by a belt drive motor (330). A belt-mounted layer engagement device is coupled to the threading belt (326) for engaging a backing layer leading edge portion (232). The backing layer collection drum (300) collects the backing layer (230) as the lamination head (200) applies the layup material (228) onto a substrate (122). The belt drive motor (330) drives the threading belt (326) over the belt rollers (328) and causes the belt-mounted layer engagement device to thread the backing layer (230) through the lamination head (200), and position the backing layer leading edge portion (232) proximate the backing layer collection drum (300).