Sheet Forming Apparatus Trimming and Adhesion Control
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Solution Overview
Problem
Existing forming apparatuses face challenges in achieving uniform temperature distribution and reliable adhesion of sheets to base materials, leading to inefficient trimming processes due to adhesion layers adhering to hands and devices, resulting in reduced productivity and potential peeling issues.
Innovation Solution
A forming apparatus and method that includes a base material jig and trimming means to perform trimming on the sheet while it is still adhered to the jig, using a blade and moving means to cut the sheet without removing the base material, and a pressing section to increase adhesive strength by pressure-sticking the sheet to the base material's outer peripheral portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base material is removed from the jig after adhesion for trimming, then the sheet can be trimmed, but the adhesion layer adheres to hands and devices causing productivity loss
Solution Approach 1:
The trimming operation is performed before removing the base material from the jig. By conducting the trimming process while the sheet is still adhered to the base material on the jig, the adhesion layer does not come into contact with hands or external devices, thus preventing unwanted adhesion and maintaining productivity.
2Temperature
If in-chamber radiation heating is used, then the sheet can be heated, but elongation occurs causing non-uniform temperature distribution and position shift
Solution Approach 1:
The patent replaces in-chamber radiation heating with heat plate heating. The heat plate directly contacts the sheet to provide controlled, uniform heating without causing elongation. This substitution of heating method eliminates the temperature distribution non-uniformity and position shift problems associated with radiation heating.
3Volume of moving object
If the volume of chambers is large, then the forming capacity is sufficient, but depressurization takes time increasing cycle time
Solution Approach 1:
The patent divides the forming system into separate components: the bottom frame with its chamber and the heat plate with its separate chamber. This segmentation allows for more efficient depressurization of each smaller chamber independently, reducing the overall cycle time while maintaining sufficient forming capacity through the coordinated operation of both chambers.
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 approach prevents adhesion layers from adhering to hands or devices, enhances the adhesive strength of the sheet to the base material, and improves productivity by allowing for efficient trimming and pressure-sticking without removing the base material, thereby reducing peeling defects.
Implementation Method 1
a heat plate having a heating surface capable of coming into close contact with a frame upper edge portion of the bottom frame, and makes a sheet adhere to a shaped mold or the base material by disposing the sheet between the bottom frame and the heat plate and thermoforming the sheet
Implementation Method 2
the bottom frame is provided with depressurization means which can fix the sheet to the frame upper edge portion and depressurizes the space below the sheet
Implementation Method 3
the heat plate is provided with depressurization means for suctioning the heating surface side
Data Source
AI summary
A forming apparatus includes a base material jig provided on a base, adhesion means for making a sheet having an adhesion layer and covered to a base material retained on the base material jig adhere to the base material, and trimming means for performing trimming on the sheet with respect to the base material with the sheet adhered thereto, in a state in which the base material is not removed from the base material jig.