Stamp-Laminating Film Web Tool for Simultaneous Punching and Bonding
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Solution Overview
Problem
Existing methods for producing laminates require complex and costly equipment, with high precision and risk of thermomechanical stresses leading to detachment of film webs, and existing solutions complicate the process with multiple steps and high equipment complexity.
Innovation Solution
A method where the second film is punched and laminated simultaneously with the structured first film using a single tool, allowing for precise alignment and thermal bonding, reducing equipment complexity and process steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two film webs are brought onto one another with monitored position and compensated offset, then alignment precision is improved, but equipment complexity and cost increase
Solution Approach 1:
The patent combines the punching operation and lamination operation into a single integrated tool and process step. The punching tool simultaneously punches the second film and bonds it to the first film, eliminating the need for separate alignment monitoring and compensation systems while maintaining precise alignment through the integrated nature of the operation.
Solution Approach 2:
The integrated tool performs multiple functions: it punches the second film, positions it relative to the first film, and bonds the films together in a single operation. This multi-functional approach replaces complex separate systems for alignment monitoring and compensation, achieving precise alignment while reducing equipment complexity.
2Manufacturing precision
If tensile force is applied to one film web for offset compensation, then alignment is improved, but thermomechanical stresses occur leading to deformation and detachment
Solution Approach 1:
By merging the punching and lamination operations into a single simultaneous process, the patent eliminates the need to apply tensile forces for offset compensation. The integrated tool achieves precise alignment and bonding in one step, avoiding the thermomechanical stresses that would cause deformation and detachment.
3Manufacturing precision
If individual film web sections are fed in separately for gluing, then misalignment is eliminated, but equipment complexity and production time increase
Solution Approach 1:
The patent merges the punching and lamination operations into a single simultaneous process using an integrated tool. This allows continuous feeding of film webs without the need to stop and glue individual sections separately, maintaining high alignment precision while significantly improving production speed and continuity.
4Ease of operation
If punching and laminating are performed in separate steps, then process control is simplified, but equipment complexity and production time increase
Solution Approach 1:
The patent combines punching and lamination into a single integrated tool and process step. This simultaneous operation simplifies process control by eliminating the coordination between separate steps while reducing equipment complexity compared to having separate punching and lamination systems.
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 method simplifies the laminate production process, ensures precise alignment, and reduces costs by integrating punching and laminating into a single step, while maintaining structural integrity and allowing for efficient continuous processing.
Implementation Method 1
it can even be provided that the heat is provided by the tool at the same time in order to attach at least a second film to the first film
Data Source
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Figure 3~4
AI summary
The invention relates to a method for producing a laminate (16, 26, 56) from at least two films, wherein at least one first film (1, 31, 61) is structured and is subsequently laminated with at least one second film (2, 3, 62). In one single production step, at least one second film is stamped using at least one tool (6, 12, 66) and is laminated with the structured first film at the same time, wherein the films are conveyed, at least intermittently, to the at least one tool. The invention further relates to a laminate produced with such a method, and to a device for producing a laminate using a method as described, wherein the device is suitable for conveying a first film and at least one second film. In some regions, the films are oriented parallel to one another, and the device comprises at least one tool with which at least one second film can be stamp-laminated onto the first film.