Vacuum Roller Device for Automated Cover Layer Detachment
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Solution Overview
Problem
The manual separation of the cover layer from the adhesive layer in multi-layered identity, value, or security documents is time-consuming and expensive, and existing delamination systems are inefficient.
Innovation Solution
A device comprising motor-driven rollers with radial suction devices that securely fix and detach the cover layer from the adhesive layer using vacuum technology, allowing for automated separation without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual separation of the cover layer from the adhesive layer is used, then the process is simple and reliable, but it is very time-consuming and expensive
Solution Approach 1:
The patent employs vacuum suction devices integrated into the rollers to automatically grasp and separate the cover layer from the adhesive layer. The vacuum system creates negative pressure to hold and manipulate the layers, enabling automated separation without manual intervention, thus increasing productivity while maintaining reliability through controlled pneumatic forces.
Solution Approach 2:
The manual mechanical separation process is replaced by an automated system combining vacuum technology and roller mechanics. The rollers with integrated suction devices substitute human hands, performing the separation task through coordinated mechanical motion and vacuum control, thereby eliminating the time-consuming and expensive manual operation.
2Extent of automation
If existing delamination systems with vacuum rollers are used, then automated separation is achieved, but the system is complex and requires metal sheets integrated into rollers
Solution Approach 1:
The patent combines the vacuum generation system and the roller structure into a single integrated unit. The suction devices are directly formed as part of the roller assembly, eliminating the need for separate vacuum chambers and metal sheet integrations. This merging simplifies the overall structure while maintaining automated separation capability.
Solution Approach 2:
The complex metal sheet integration requirement from existing systems is extracted and eliminated. The patent achieves automated separation using a simplified roller design where the suction function is inherently integrated without requiring additional metal components, reducing structural complexity while preserving automation.
3Reliability
If the cover is securely fixed to the first roller, then reliable transport is achieved, but the cover layer becomes difficult to detach
Solution Approach 1:
The vacuum suction is applied periodically rather than continuously. The system activates vacuum to secure the cover for transport, then deactivates it to facilitate easy detachment. This periodic application of suction force allows the cover to be firmly held during transport and easily released when needed, resolving the contradiction between secure fixing and easy detachment.
Solution Approach 2:
The suction force is made dynamic rather than static. The vacuum level and application points are adjusted during the process cycle - high suction during transport for reliability, reduced or localized suction during detachment for ease of operation. This dynamic control allows the system to adapt to different operational phases, achieving both secure fixing and easy detachment.
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 efficient, automated detachment of the cover layer from the multi-layered layer, reducing production time and costs while ensuring reliable handling and collection of the cover layer.
Implementation Method 1
a first suction device (210), which is oriented radially with respect to its longitudinal axis (206) and is arranged or formed on the first roller (202) and is flow-connected to a vacuum device and is configured in such a way as to at least partially fix the cover (102) to the first roller (202)
Data Source
Figure 1~2b
Figure 2c~2f
Figure 3
AI summary
The invention relates to a device (200) for removing a cover layer (304) from a multilayer layer (300) attached to a cover (102) of an identification, value or security document (100), comprising a first roller (202) driven continuously or intermittently by a motor for conveying the cover (102) and a second roller (202) aligned with respect to the first roller (202) such that the cover (102) is at least temporarily between the two rollers (202;204) formed gap, wherein at least one first suction device (210) is arranged or formed radially with respect to its longitudinal axis (206) on the first roller (202), which is fluidly connected to a vacuum device and is configured to fix the cover (102) at least partially to the first roller (202), and wherein at least one second suction device (220) is arranged or formed radially with respect to its longitudinal axis (206) on the second roller (204), which is fluidly connected to the vacuum device or a second vacuum device and is configured to detach the cover layer (304) from the multilayer layer (300) upon contact with the cover (102). The invention also relates to a method for detaching a cover layer (304) from a multilayer layer (300).