Transfer Lamination Using Flexible Membrane Applicator
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Solution Overview
Problem
Existing transfer lamination methods require high pressure and temperature for effective adhesion of decorative layers to substrates, which can be costly and inefficient, and often result in unprofessional-looking or durable decorative elements when exposed to the elements.
Innovation Solution
A method involving a transfer laminate heated to 60-95°C for lamination onto a still moist and tacky lacquer layer on the substrate, allowing for good adhesion without residue and enabling the decorative element to be integrated as an integral part of the paint layer, using a device with a flexible membrane system for controlled pressure and temperature application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high pressure and temperature are used for transfer lamination, then adhesion strength is improved, but manufacturing cost and energy consumption increase
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperatures (150-200°C) to a reduced temperature range (60-95°C), and adjusts the timing parameter by applying the decorative layer during the flash-off period when the base coat is still moist. This parameter change allows achieving sufficient adhesion strength without the high energy consumption associated with conventional high-temperature lamination processes.
2Strength
If high pressure and temperature are used for transfer lamination, then adhesion strength is improved, but system complexity and conversion cost increase
Solution Approach 1:
The patent applies the decorative transfer laminate during the flash-off period of the base coat, which is a preliminary stage before the base coat fully dries. By performing the lamination action at this preliminary stage when the base coat is still moist and tacky, sufficient adhesion is achieved without requiring complex high-pressure heating systems, thereby reducing device complexity and conversion cost.
3Ease of manufacture
If conventional transfer lamination is used, then decorative elements are applied, but durability and professional appearance deteriorate when exposed to elements
Solution Approach 1:
By applying the decorative transfer laminate during the flash-off period when the base coat is still moist, the decorative layer becomes integrated into the paint system before curing. This preliminary timing ensures that the decorative element is bonded at a molecular level during the curing process, resulting in superior durability and professional appearance that withstands environmental exposure, while maintaining ease of application through the transfer laminate method.
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
Achieves strong adhesion between the decorative layer and substrate coating, allowing for the carrier film to be removed without damage, creating a high-quality paint layer with the decorative element perceived as integral, while reducing the need for costly system conversions and improving durability.
Implementation Method 1
the decorative layer on the carrier film is completely and non-destructively detached from the carrier film and transferred or transferred completely and non-destructively in the form of a skin, pellicle or layer to the lacquer layer on the substrate
Implementation Method 2
the carrier film can be separated and removed without leaving any residue from the transferred decorative element and from the substrate coating
Data Source
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Figure 3~4
Figure 5
AI summary
A transfer laminate (35), comprising a carrier film having an adhering decorative element having a solid, pigmented, partially cured decorative layer, is laminated on the decoration side onto a substrate (40) having a temperature between 50 and 70°C on the decoration side, on which substrate a coating that can be painted over has been applied in the course of a traditional process. The paint layer of the coating that was applied last is still moist and tacky after the intermediate drying thereof. The transfer laminate (35) is laminated onto the still moist and tacky paint layer on the substrate (40), and at least the region of the transfer laminate (35) containing the decorative element is pressed onto the substrate coating over the entire area at a pressure of 0.2 to 5.0 bar for 40 to 240 seconds. Then the carrier film is quickly cooled to a temperature less than 20°C and then removed from the substrate coating, wherein the decorative element remains on the substrate coating. The device for transfer lamination forms an applicator (10), which comprises: two flexible membranes (20, 22), which are both clamped pressure-tight on a common frame (12) along the perimeter of the membranes in such a way that an intermediate space is created therebetween, in which a flexible warm- or hot-water layer (27) can be enclosed; a chamber (30), which can be filled with compressed air, wherein overall such an arrangement is created that a gradual introduction of compressed air into the chamber (30) moves the two flexible membranes (20, 22) and the flexible warm- or hot-water layer (27) jointly in the manner of a balloon onto the substrate surface (42) to be coated in order to apply the transfer laminate (35) to and press the transfer laminate onto said substrate surface (42) without bubbles.