Lamination Press With Servo Tooling and Air-Bearing Alignment
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Solution Overview
Problem
Existing lamination presses are large, complex, and expensive due to the need for substantial pressure/vacuum and high precision, requiring substantial electromechanical equipment, which limits their applicability and cost-effectiveness.
Innovation Solution
A lamination apparatus utilizing a servo-driven lower press with X-Y-theta tooling, air bearing stages, and a diaphragm flexure plate for precise alignment and reduced mechanical complexity, allowing for smaller, less expensive, and faster laminating operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional lamination presses use substantial pressure/vacuum and high precision equipment, then lamination quality is improved, but device size and complexity increase
Solution Approach 1:
The patent replaces traditional mechanical pressure/vacuum systems with a servo-driven lower press that uses controlled mechanical force. The X-Y-theta tooling and air bearing stages provide precise positioning without requiring substantial vacuum equipment, reducing electromechanical complexity while maintaining lamination quality.
Solution Approach 2:
The patent changes the operating parameters by using servo-driven control for precise force application instead of substantial vacuum pressure. The air bearing stages enable nanometer-level positioning precision, and the diaphragm flexure plate provides compliant contact, achieving high lamination quality through parameter optimization rather than excessive force or vacuum.
2Manufacturing precision
If traditional lamination presses use substantial electromechanical equipment, then lamination precision is improved, but cost increases
Solution Approach 1:
The patent reduces cost by replacing expensive vacuum systems and complex electromechanical equipment with a servo-driven mechanical press. The air bearing stages and diaphragm flexure plate provide the necessary precision at lower cost, making high-precision lamination more affordable.
Solution Approach 2:
The patent achieves cost reduction by optimizing parameters such as using air bearing stages for positioning instead of expensive mechanical alignment systems, and employing servo-driven control for precise force application rather than substantial vacuum equipment.
3Manufacturing precision
If traditional lamination presses use substantial pressure/vacuum systems, then lamination quality is improved, but device size increases
Solution Approach 1:
The patent reduces press size by replacing substantial vacuum systems with a compact servo-driven mechanical press. The air bearing stages and diaphragm flexure plate enable high-precision lamination in a smaller footprint, making the equipment more space-efficient.
4Manufacturing precision
If traditional lamination presses use high precision equipment, then lamination accuracy is improved, but device complexity increases
Solution Approach 1:
The patent simplifies mechanical complexity by replacing complex electromechanical equipment with a servo-driven press using air bearing stages and diaphragm flexure plate. This substitution achieves high lamination accuracy through optimized mechanical design rather than excessive complexity.
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 solution enables precise, bubble-free lamination of various surfaces with reduced size and cost, achieving a cost level of 1/10th that of traditional presses while maintaining high lamination quality.
Implementation Method 1
air bearing stages
Implementation Method 2
diaphragm flexure plate
Data Source
Figure 1
Figure 2
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AI summary
A lamination apparatus, system, and method. The apparatus, system and method are for a lamination press for laminating at least one laminating film to a subject, which may include: an upper press comprising a gel plate, an upper vacuum chamber, and tooling suitable to apply the laminating film; a lower press suitable to maintain the subject to receive the laminating film, and comprising a lower vacuum chamber, an air bearing stage, and servo-positioned tooling; and an aligner that applies the servo-positioned tooling to maintain positional balance and alignment of the subject by the air bearing stage during the laminating while enabling vertical flexure of the lower press, wherein the positional balance and alignment is substantially continuously monitored by a controller.