US20110226423A1 - Laminating device - Google Patents
Laminating device Download PDFInfo
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- US20110226423A1 US20110226423A1 US13/130,927 US200913130927A US2011226423A1 US 20110226423 A1 US20110226423 A1 US 20110226423A1 US 200913130927 A US200913130927 A US 200913130927A US 2011226423 A1 US2011226423 A1 US 2011226423A1
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- Prior art keywords
- laminating
- temperature
- roller
- rate
- arrangement according
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- 238000010030 laminating Methods 0.000 title claims abstract description 113
- 230000005855 radiation Effects 0.000 claims abstract description 19
- 230000003247 decreasing effect Effects 0.000 claims abstract description 4
- 229910052736 halogen Inorganic materials 0.000 description 34
- 150000002367 halogens Chemical class 0.000 description 34
- 230000003466 anti-cipated effect Effects 0.000 description 5
- 239000000463 material Substances 0.000 description 4
- 229920001296 polysiloxane Polymers 0.000 description 4
- 238000000034 method Methods 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000013021 overheating Methods 0.000 description 2
- 230000000630 rising effect Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B41/00—Arrangements for controlling or monitoring lamination processes; Safety arrangements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/0046—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by constructional aspects of the apparatus
- B32B37/0053—Constructional details of laminating machines comprising rollers; Constructional features of the rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/142—Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/02—Temperature
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/02—Temperature
- B32B2309/022—Temperature vs pressure profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/02—Temperature
- B32B2309/025—Temperature vs time profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/70—Automated, e.g. using a computer or microcomputer
- B32B2309/72—For measuring or regulating, e.g. systems with feedback loops
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2310/00—Treatment by energy or chemical effects
- B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
- B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
- B32B2310/0825—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using IR radiation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
- B32B37/187—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only the layers being placed in a carrier before going through the lamination process
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
- Y10T156/1702—For plural parts or plural areas of single part
- Y10T156/1712—Indefinite or running length work
- Y10T156/1741—Progressive continuous bonding press [e.g., roll couples]
Definitions
- This invention relates to a laminating device, and particularly concerns a laminating device which is able to warm up to its operating temperature within a relatively short space of time.
- Laminating devices are widely used for sealing items within translucent or transparent pouches, so that the items can be displayed and/or stored and remain protected from dirt, moisture and so on.
- one aspect of the present invention provides a laminating arrangement comprising: a laminating roller; a radiating element adapted to radiate energy therefrom towards the laminating roller; a temperature detecting arrangement, adapted to detect the temperature at the surface of the laminating roller; and a processor adapted to receive a signal from the temperature detecting arrangement and to control the intensity of radiation emitted by the radiating element, wherein: a maximum warm-up rate is defined; and during a warm-up phase of the laminating arrangement, the rate of increase in temperature at the surface of the laminating roller is determined by the processor, and the intensity of radiation emitted by the radiating element is increased if the rate of increase of temperature is less than the maximum warm-up rate, and is decreased if the rate of increase of temperature is greater than the maximum warm-up rate.
- an operating temperature being the temperature at which the laminating roller is to be maintained during laminating operations
- a maximum temperature is also defined, wherein, during the warm-up phase, the temperature of the laminating roller is increased to the maximum temperature, and wherein the maximum temperature is at least 25° C. higher than the operating temperature.
- the maximum temperature is at least 30° higher than the operating temperature.
- the maximum temperature is at least 35° higher than the operating temperature.
- a lag time is defined, and wherein, following a change in intensity of radiation emitted by the radiating element, no further change in intensity may occur until the lag time has expired.
- the lag time is at least substantially as long as the time taken for the laminating roller to complete a revolution at a rate of rotation used during laminating operations.
- the lag time is less than approximately the time taken for the laminating roller to form two complete revolutions at the rotation rate employed during laminating operations.
- the laminating roller is rotated whenever the radiating element is activated.
- the intensity of energy radiated from the radiating element is controlled, in accordance with the detected temperature of the surface of the laminating roller, to maintain the surface of the laminating roller at or near an operating temperature thereof.
- a plurality of high temperature bands are defined above the operating temperature, and the intensity of radiation emitted by the radiating element is controlled in dependence of the high temperature band in which the detected temperature of the surface of the laminating roller falls.
- one or more low-temperature bands are defined below the operating temperature and wherein the intensity of the radiation emitted by the radiating element is controlled in accordance with the low temperature band in which the detected temperature of the surface of the laminating rollers falls.
- one or more fans are provided, the fans being positioned to direct a stream of air across a surface of the laminating roller to cool the laminating roller.
- the rate of rotation of the one or more fans is controlled in accordance with the detected temperature at the surface of the laminating roller.
- the laminating arrangement is configured so that, after passing over the surface of the laminating roller, air blown by the one or more fans is directed towards an exit point of the laminating roller.
- FIG. 1 is a schematic view of components of a laminating machine, of the type that may be used for the present invention
- FIG. 2 shows a graph of the temperature of the surface of one of the rollers of the machine of FIG. 1 during warm up and subsequent laminating operations
- FIG. 3 is a view of further components of a laminating machine that may be used for the present invention.
- the laminating machine includes a pair of rollers 1 , 2 .
- Each roller comprises a solid core 3 , made from a material such as steel, with a relatively thin silicone covering 4 being formed around the core 3 .
- the thickness of the silicone covering 4 with respect to the core 3 is exaggerated in FIG. 1 for the purposes of clarity.
- the rollers 1 , 2 are parallel with one another, and are preferably biased into contact with one another by means of a spring-loaded element (not shown).
- the rollers 1 , 2 are rotatable around respective spindles 5 , and may be driven to rotate in opposite directions by a gearing system (not shown) which is in turn connected to a drive motor.
- a gearing system (not shown) which is in turn connected to a drive motor.
- the upper roller 1 will be driven in an anti-clockwise direction
- the lower roller 2 will be driven in a clockwise direction, so that items to be laminated may be drawn between the rollers 1 , 2 from left to right.
- Respective halogen lamps 6 are provided to radiate heat energy to the upper and lower rollers 1 , 2 .
- Each halogen lamp 6 comprises an elongate halogen bulb 7 .
- the halogen bulbs 7 are approximately the same length as the rollers 1 , 2 , and are arranged to be substantially parallel therewith.
- a reflector 8 is provided around each halogen bulb 7 .
- the reflectors 8 are formed from a reflective material, such as aluminium.
- Each reflector 8 is preferably arranged so that radiation emitted from the halogen bulb 7 is reflected from the internal surfaces of the reflector 9 , and is concentrated so as to exit the reflector 8 in a particular direction.
- the reflector 8 that is provided around the halogen bulb 7 that is provided to heat the upper roller 1 is arranged so that radiated energy is reflected to leave the reflector 8 in a direction directly towards the upper roller 1 , as indicated by the arrow 9 .
- the reflector 8 provided around the halogen bulb 7 that is arranged to heat the lower roller 2 concentrates radiated energy and directs it towards the lower roller 2 , as indicated by the arrows 10 .
- each reflector 8 may be parabolic.
- each reflector 8 is also elongate, is approximately the same length as the halogen bulb 7 , and is arranged to be parallel with the halogen bulb 7 , having a substantially consistent cross-sectional shape along its length.
- Each reflector 8 is therefore generally trough-shaped.
- the components as illustrated in FIG. 1 are arranged to heat the rollers from ambient temperature to operational temperature in the shortest possible time. For this reason, powerful halogen bulbs 7 are provided, and the halogen bulbs 7 are provided relatively close to the surfaces of the rollers 1 , 2 —in preferred embodiments of the invention, the distance between each bulb 7 and the respective roller is between 4 mm and 10 mm.
- the halogen bulbs 7 may have power ratings up to several hundred watts. For instance, an A3-size laminating device will require a 600 w bulb in order to heat the rollers 1 , 2 to the required operating temperature in less than one minute. An A4 laminating device will require a 400 w bulb to warm up in this time. These values are approximate, however.
- the temperature of the surface of each roller 1 , 2 is monitored by a temperature detecting arrangement 15 (shown schematically in FIG. 1 )
- the temperature of the surfaces of the rollers 1 , 2 may be measured directly by any suitable means, for instance by one or more bimetallic strips placed at or on the surface of each roller 1 , 2 .
- the output from the temperature detecting arrangement 15 is fed to a processor 16 of the laminating machine.
- the processor 16 is also operable to control the operation of the halogen bulbs 7 , by varying the power supply to the halogen bulbs 7 , or by turning the halogen bulbs 7 off entirely.
- the operation of the laminating machine will now be described, when the laminating machine is first switched on.
- the rollers 1 , 2 are, initially, substantially at the ambient temperature of the surroundings.
- the halogen bulbs 7 are switched on, and radiation from the bulbs 7 is directed towards the surfaces of the rollers 1 , 2 .
- a maximum warm-up rate for the rollers 1 , 2 Stored in a memory that is accessible by the processor 16 is a maximum warm-up rate for the rollers 1 , 2 .
- This rate represents the fastest rate at which power, in the form of heat energy, may be delivered to the surfaces of the rollers 1 , 2 by halogen bulbs 7 of the type used in the laminating machine, without incurring a significant risk of damage to the surfaces of the rollers 1 , 2 .
- the rate at which the temperatures of the roller surfaces increases is compared with the stored maximum warm-up rate.
- the intensity of the halogen bulbs 7 may be increased, although of course if the halogen bulbs 7 are already at their maximum intensity then further increase will not be possible.
- the intensity of the halogen bulbs 7 may be decreased.
- FIG. 2 a graph of temperature with respect to time is shown, following switching on of the laminating machine.
- the temperature 11 of the surfaces of the rollers 1 , 2 rises, and is maintained as close as possible to the maximum warm-up rate 12 by the feedback arrangement described above.
- a maximum temperature T max is defined, and when the temperature of the surfaces of rollers 1 , 2 reaches the maximum temperature, the warm-up phase W is complete.
- the laminator is ready to perform a first laminating operation, and an outward indication of this is preferably provided, for instance the switching on of a green “ready” lamp on an exterior of the laminating machine.
- a roller may be heated to the maximum temperature T max within around 30 seconds. Because the rollers have been heated up in a short space of time, the majority of the heat energy that has been transferred to the rollers 1 , 2 will be concentrated at the very outermost portions thereof, and heat energy will not have had time to be transmitted to inner portions of the coverings 4 of the rollers 1 , 2 . Therefore, when a first pouch to be laminated is passed between the rollers 1 , 2 , the temperature of the rollers 1 , 2 will drop sharply, as the heat energy concentrated at the very outer edges of the rollers 1 , 2 will be transmitted to the pouch.
- the maximum temperature T max is considerably higher than the intended operating temperature T op of the laminating machine, with the intention being that, when the first pouch, or few pouches, pass between the rollers 1 , 2 , the temperature of the rollers 1 , 2 will drop to the operating temperature T op .
- the operating temperature T op is around 110° C.
- the maximum temperature T max however, preferably set to be around 150° C. Referring again to FIG. 2 , it can be seen that in an initial use period I, the temperature falls rapidly from the maximum temperature T max to the operating temperature T op .
- the maximum temperature T max is at least 25° C. higher than the operating temperature T op . More preferably, the difference between these temperatures is at least 30° C., and still more preferably the difference between these temperatures is at least 35° C.
- the laminator will enter an operation period O, in which the operating temperature of the rollers 1 , 2 will be maintained for subsequent laminating operations.
- each roller may be around 20 cm, and the throughput rate of the laminating device may be around 300 cm per minute. This means that each roller makes a complete revolution in approximately 4 seconds, and the processor 16 of the laminating machine may therefore be set so that, following a change in intensity of the radiation delivered by the halogen bulbs 7 , and further changes in the intensity may be applied for a period of at least 4 seconds. This will help to ensure that localised “hot spots” on the surfaces of the rollers 1 , 2 do not occur.
- the time lag following a change of bulb intensity during which no further changes in intensity may be made is at least the time taken for one complete revolution of one of the rollers 1 , 2 .
- the time lag may be set to be longer than this, but is preferably not longer than the time taken for two complete revolutions of one of the rollers 1 , 2 .
- the machine may also include one or more fans 13 , which are arranged to blow air over the surfaces of the rollers 1 , 2 , thereby cooling the surfaces.
- the one or more fans 13 may be activated when the temperature of the surfaces of the rollers 1 , 2 exceeds the target operating temperature by a predetermined amount.
- the lowest intensity of radiation may be supplied by each of the halogen bulbs 7 (short of the halogen bulbs 7 being switched off) will be sufficiently high that, if there is a long gap between laminating operations, the surfaces of the rollers 1 , 2 may overheat. During the times between laminating operations, therefore, the fans 13 may be activated to trim excess heat from the rollers 1 , 2 , and this may occur while the halogen bulbs 7 are still switched on.
- a look-up table will be used to control the bulb intensity. For instance, if the operating temperature T op is 110°, a first high temperature band H 1 may be defined between 110° and 115°. A nominal bulb intensity is defined, which is expected to maintain the surfaces of the rollers 1 , 2 at the operating temperature during normal operation. If the temperature of the surfaces of the rollers 1 , 2 is detected to be within the first high temperature band H 1 , however, then the intensity of the bulbs 7 may be reduced by a preset amount, for instance to 70% of the nominal intensity. Preferably, a second high temperature band H 2 is defined between 115° or 120°, and a further reduction intensity may be defined with respect to this band. Further high temperature bands may also be defined.
- low temperature bands may be defined.
- a first low temperature band H 1 may be set to be between 105° and 110°, and if the detected temperature falls within this band H 1 then the intensity of the bulbs 7 may be increased to 130% of the nominal intensity.
- the widths of the bands, and the bulb intensities associates with these bands are not limited to those described above, and may be set during a calibration process to any suitable values.
- the operation of the fans 13 may be such that the fans 13 are activated if the detected temperature of the surfaces of the rollers 1 , 2 falls within the temperature bands.
- These temperature bands may correspond to those defined for the bulb intensity, or alternatively may be defined separately.
- the fans 13 may be operated to rotate at varying rates, and it will be understood that the fans 13 may be operated to rotate at a higher rate if the detected temperature of the rollers 1 , 2 falls within a higher band.
- the fans 13 and other components of the laminating machine are configured so that air blown by the fans 13 is directed, after passing over the surface of one of the laminating rollers 1 , 2 , towards an exit point of the laminating rollers 1 , 2 .
- the shape of internal surfaces (not shown) of the housing 14 of the laminator may be angled so that, once air blown by the fans 13 is passed over the surface of one of the rollers 1 , 2 , the air is deflected by this internal surfaces towards the exit point of the rollers 1 , 2 .
- FIG. 3 A schematic view of the flow of air in these embodiments is shown in FIG. 3 .
- laminated pouches exiting the rollers 1 , 2 may be heated to a very high temperature.
- a directing of air from the fans 13 towards the exit point of the rollers 1 , 2 will help to cool these pouches, which will help prevent distortion of the pouches, and also help to ensure that the pouches are at a reasonable temperature to be grasped by a user as they exit the laminating machine.
- the laminating machine may be included to warm up in a longer time period, for instance around one minute.
- some of the measures described above may not be necessary.
- the laminating device is configured to warm up in around one minute, it is anticipated that the “overshooting” of the temperature to a maximum temperature which is significantly above the operating temperature may not be necessary.
- embodiments of the present invention may provide laminating machines which warm up in a considerable shorter time than is presently practically possible.
Abstract
A laminating arrangement comprising: a laminating roller; a radiating element adapted to radiate energy therefrom towards the laminating roller; a temperature detecting arrangement, adapted to detect the temperature at the surface of the laminating roller; and a processor adapted to receive a signal from the temperature detecting arrangement device and to control the intensity of radiation emitted by the radiating element, wherein: a maximum warm-up rate is defined; and during a warm-up phase of the laminating arrangement, the rate of increase in temperature at the surface of the laminating roller is determined by the processor, and the intensity of radiation emitted by the radiating element is increased if the rate of increase of temperature is less than the maximum warm-up rate, and is decreased if the rate of increase of temperature is greater than the maximum warm-up rate.
Description
- This invention relates to a laminating device, and particularly concerns a laminating device which is able to warm up to its operating temperature within a relatively short space of time.
- Laminating devices are widely used for sealing items within translucent or transparent pouches, so that the items can be displayed and/or stored and remain protected from dirt, moisture and so on.
- One problem with most conventional laminating machines is that, when the machine is initially switched on, it takes a relatively long time before the machine is ready to perform a laminating operation. This is because the rollers of the machine must be heated up to a high temperature. In conventional laminating machines, each roller is partially surrounded by a heavy “shoe” formed from a material such as aluminium. The shoes are heated, typically by resistance heating, and heat energy is transferred from the shoes to the rollers by radiation and convection.
- Whilst shoes of this type have proved to be effective at maintaining the rollers at the desired operating temperature, it will be appreciated that laminating machines using this technique will take a considerable length of time for the rollers to reach a suitable laminating temperature.
- More recently, it has been proposed to heat the rollers by directing radiation from halogen bulbs onto the surfaces of the rollers. The heat produced by halogen bulbs is, however, intense, and it has proved difficult to heat rollers consistently and reliably in this manner. It has also been found that, if the surfaces of the rollers (which are typically formed silicone) are overheated, they may become permanently damaged, which may render the entire machine inoperable.
- It is an objective of the present invention to provide an improved laminating device.
- Accordingly, one aspect of the present invention provides a laminating arrangement comprising: a laminating roller; a radiating element adapted to radiate energy therefrom towards the laminating roller; a temperature detecting arrangement, adapted to detect the temperature at the surface of the laminating roller; and a processor adapted to receive a signal from the temperature detecting arrangement and to control the intensity of radiation emitted by the radiating element, wherein: a maximum warm-up rate is defined; and during a warm-up phase of the laminating arrangement, the rate of increase in temperature at the surface of the laminating roller is determined by the processor, and the intensity of radiation emitted by the radiating element is increased if the rate of increase of temperature is less than the maximum warm-up rate, and is decreased if the rate of increase of temperature is greater than the maximum warm-up rate.
- Conveniently, an operating temperature is defined, being the temperature at which the laminating roller is to be maintained during laminating operations, and a maximum temperature is also defined, wherein, during the warm-up phase, the temperature of the laminating roller is increased to the maximum temperature, and wherein the maximum temperature is at least 25° C. higher than the operating temperature.
- Advantageously, the maximum temperature is at least 30° higher than the operating temperature.
- Preferably, the maximum temperature is at least 35° higher than the operating temperature.
- Conveniently, a lag time is defined, and wherein, following a change in intensity of radiation emitted by the radiating element, no further change in intensity may occur until the lag time has expired.
- Advantageously, the lag time is at least substantially as long as the time taken for the laminating roller to complete a revolution at a rate of rotation used during laminating operations.
- Preferably, the lag time is less than approximately the time taken for the laminating roller to form two complete revolutions at the rotation rate employed during laminating operations.
- Advantageously, the laminating roller is rotated whenever the radiating element is activated.
- Conveniently, during an operation phase of the laminating arrangement, which follows the warm-up phase, the intensity of energy radiated from the radiating element is controlled, in accordance with the detected temperature of the surface of the laminating roller, to maintain the surface of the laminating roller at or near an operating temperature thereof.
- Preferably, a plurality of high temperature bands are defined above the operating temperature, and the intensity of radiation emitted by the radiating element is controlled in dependence of the high temperature band in which the detected temperature of the surface of the laminating roller falls.
- Advantageously, one or more low-temperature bands are defined below the operating temperature and wherein the intensity of the radiation emitted by the radiating element is controlled in accordance with the low temperature band in which the detected temperature of the surface of the laminating rollers falls.
- Conveniently, one or more fans are provided, the fans being positioned to direct a stream of air across a surface of the laminating roller to cool the laminating roller.
- Advantageously, the rate of rotation of the one or more fans is controlled in accordance with the detected temperature at the surface of the laminating roller.
- Preferably, the laminating arrangement is configured so that, after passing over the surface of the laminating roller, air blown by the one or more fans is directed towards an exit point of the laminating roller.
- In order that the present invention may be more readily understood, embodiments thereof will now be described, by way of example, in which:
-
FIG. 1 is a schematic view of components of a laminating machine, of the type that may be used for the present invention; -
FIG. 2 shows a graph of the temperature of the surface of one of the rollers of the machine ofFIG. 1 during warm up and subsequent laminating operations; and -
FIG. 3 is a view of further components of a laminating machine that may be used for the present invention. - Turning firstly to
FIG. 1 , some of the internal components of a laminating machine embodying the present invention are shown. The laminating machine includes a pair ofrollers solid core 3, made from a material such as steel, with a relatively thin silicone covering 4 being formed around thecore 3. The thickness of the silicone covering 4 with respect to thecore 3 is exaggerated inFIG. 1 for the purposes of clarity. - The
rollers rollers respective spindles 5, and may be driven to rotate in opposite directions by a gearing system (not shown) which is in turn connected to a drive motor. With reference toFIG. 1 , theupper roller 1 will be driven in an anti-clockwise direction, and thelower roller 2 will be driven in a clockwise direction, so that items to be laminated may be drawn between therollers Respective halogen lamps 6 are provided to radiate heat energy to the upper andlower rollers halogen lamp 6 comprises an elongate halogen bulb 7. In preferred embodiments of the invention, the halogen bulbs 7 are approximately the same length as therollers - A
reflector 8 is provided around each halogen bulb 7. Thereflectors 8 are formed from a reflective material, such as aluminium. Eachreflector 8 is preferably arranged so that radiation emitted from the halogen bulb 7 is reflected from the internal surfaces of the reflector 9, and is concentrated so as to exit thereflector 8 in a particular direction. With reference toFIG. 1 , thereflector 8 that is provided around the halogen bulb 7 that is provided to heat theupper roller 1 is arranged so that radiated energy is reflected to leave thereflector 8 in a direction directly towards theupper roller 1, as indicated by the arrow 9. Similarly, thereflector 8 provided around the halogen bulb 7 that is arranged to heat thelower roller 2 concentrates radiated energy and directs it towards thelower roller 2, as indicated by thearrows 10. - It will be understood that at least a part of the cross-section of each
reflector 8 may be parabolic. Preferably, eachreflector 8 is also elongate, is approximately the same length as the halogen bulb 7, and is arranged to be parallel with the halogen bulb 7, having a substantially consistent cross-sectional shape along its length. Eachreflector 8 is therefore generally trough-shaped. - The components as illustrated in
FIG. 1 are arranged to heat the rollers from ambient temperature to operational temperature in the shortest possible time. For this reason, powerful halogen bulbs 7 are provided, and the halogen bulbs 7 are provided relatively close to the surfaces of therollers - The halogen bulbs 7 may have power ratings up to several hundred watts. For instance, an A3-size laminating device will require a 600 w bulb in order to heat the
rollers - As discussed above, if the silicone material that forms the
outer surfaces 4 of therollers - The temperature of the surface of each
roller FIG. 1 ) In preferred embodiments, the temperature of the surfaces of therollers roller temperature detecting arrangement 15 is fed to aprocessor 16 of the laminating machine. Theprocessor 16 is also operable to control the operation of the halogen bulbs 7, by varying the power supply to the halogen bulbs 7, or by turning the halogen bulbs 7 off entirely. - The operation of the laminating machine will now be described, when the laminating machine is first switched on. The
rollers rollers - Stored in a memory that is accessible by the
processor 16 is a maximum warm-up rate for therollers rollers rollers rollers - If the temperature of the surfaces of the
rollers - Conversely, if the
temperature detecting arrangement 15 indicates that the temperature of the surfaces of therollers - It will be understood that the rate at which the temperature of the surfaces of the
rollers - Referring to
FIG. 2 , a graph of temperature with respect to time is shown, following switching on of the laminating machine. During a warm-up period W, thetemperature 11 of the surfaces of therollers up rate 12 by the feedback arrangement described above. - A maximum temperature Tmax is defined, and when the temperature of the surfaces of
rollers - It is anticipated that, using the above technique, a roller may be heated to the maximum temperature Tmax within around 30 seconds. Because the rollers have been heated up in a short space of time, the majority of the heat energy that has been transferred to the
rollers coverings 4 of therollers rollers rollers rollers - For this reason, the maximum temperature Tmax is considerably higher than the intended operating temperature Top of the laminating machine, with the intention being that, when the first pouch, or few pouches, pass between the
rollers rollers - In preferred embodiments of the invention, the operating temperature Top is around 110° C. The maximum temperature Tmax however, preferably set to be around 150° C. Referring again to
FIG. 2 , it can be seen that in an initial use period I, the temperature falls rapidly from the maximum temperature Tmax to the operating temperature Top. - In further embodiments of the invention, the maximum temperature Tmax is at least 25° C. higher than the operating temperature Top. More preferably, the difference between these temperatures is at least 30° C., and still more preferably the difference between these temperatures is at least 35° C.
- Following the initial use period, the laminator will enter an operation period O, in which the operating temperature of the
rollers - As discussed above, the use of powerful halogen bulbs 7 provided in close proximity to the surfaces of the
rollers rollers rollers rollers - One way in which this may be achieved is to ensure that there must be a minimum time lag between changes in the intensity of the energy supplied by the halogen bulbs 7. For instance, the circumference of each roller may be around 20 cm, and the throughput rate of the laminating device may be around 300 cm per minute. This means that each roller makes a complete revolution in approximately 4 seconds, and the
processor 16 of the laminating machine may therefore be set so that, following a change in intensity of the radiation delivered by the halogen bulbs 7, and further changes in the intensity may be applied for a period of at least 4 seconds. This will help to ensure that localised “hot spots” on the surfaces of therollers - In preferred embodiments, the time lag following a change of bulb intensity during which no further changes in intensity may be made is at least the time taken for one complete revolution of one of the
rollers rollers - Referring again to
FIG. 3 , the machine may also include one ormore fans 13, which are arranged to blow air over the surfaces of therollers more fans 13 may be activated when the temperature of the surfaces of therollers - It is anticipated that, in certain embodiments of the invention, the lowest intensity of radiation may be supplied by each of the halogen bulbs 7 (short of the halogen bulbs 7 being switched off) will be sufficiently high that, if there is a long gap between laminating operations, the surfaces of the
rollers fans 13 may be activated to trim excess heat from therollers - During the operation period O of the laminating machine, feedback from the temperature detecting arrangement will preferably continue to be used to control the intensity of radiation provided by the halogen bulbs 7. In preferred embodiments, a look-up table will be used to control the bulb intensity. For instance, if the operating temperature Top is 110°, a first high temperature band H1 may be defined between 110° and 115°. A nominal bulb intensity is defined, which is expected to maintain the surfaces of the
rollers rollers - Similarly, low temperature bands may be defined. A first low temperature band H1 may be set to be between 105° and 110°, and if the detected temperature falls within this band H1 then the intensity of the bulbs 7 may be increased to 130% of the nominal intensity.
- The widths of the bands, and the bulb intensities associates with these bands, are not limited to those described above, and may be set during a calibration process to any suitable values.
- It is also anticipated that the operation of the
fans 13, if thesefans 13 are provided, may be such that thefans 13 are activated if the detected temperature of the surfaces of therollers fans 13 may be operated to rotate at varying rates, and it will be understood that thefans 13 may be operated to rotate at a higher rate if the detected temperature of therollers - In preferred embodiments of the invention, the
fans 13 and other components of the laminating machine are configured so that air blown by thefans 13 is directed, after passing over the surface of one of thelaminating rollers laminating rollers housing 14 of the laminator may be angled so that, once air blown by thefans 13 is passed over the surface of one of therollers rollers - A schematic view of the flow of air in these embodiments is shown in
FIG. 3 . - As discussed above, due to the intensity of the halogen bulb 7 it is possible that, more particularly during the first few laminating operations after the machine has switched on, laminated pouches exiting the
rollers fans 13 towards the exit point of therollers - In variations of the invention, the laminating machine may be included to warm up in a longer time period, for instance around one minute. In these embodiments, some of the measures described above may not be necessary. For instance, if the laminating device is configured to warm up in around one minute, it is anticipated that the “overshooting” of the temperature to a maximum temperature which is significantly above the operating temperature may not be necessary. Also, it is anticipated that it will not be necessary to place the halogen bulbs so close to the
rollers - It will be understood that embodiments of the present invention may provide laminating machines which warm up in a considerable shorter time than is presently practically possible.
- When used in this specification and claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.
Claims (17)
1. A laminating arrangement comprising:
a laminating roller;
a radiating element adapted to radiate energy therefrom towards the laminating roller;
a temperature detecting arrangement, adapted to detect the temperature at a surface of the laminating roller; and
a processor adapted to receive a signal from the temperature detecting arrangement and to control the intensity of radiation emitted by the radiating element, wherein:
a maximum warm-up rate is defined; and
during a warm-up phase of the laminating arrangement, the rate of increase in temperature at the surface of the laminating roller is determined by the processor, and the intensity of radiation emitted by the radiating element is increased if the rate of increase of temperature is less than the maximum warm-up rate, and is decreased if the rate of increase of temperature is greater than the maximum warm-up rate.
2. A laminating arrangement according to claim 1 , wherein an operating temperature is defined, being the temperature at which the laminating roller is to be maintained during laminating operations, and a maximum temperature is also defined, wherein, during the warm-up phase, the temperature of the laminating roller is increased to the maximum temperature, and wherein the maximum temperature is at least 25° C. higher than the operating temperature.
3. A laminating arrangement according to claim 2 , wherein the maximum temperature is at least 30° C. higher than the operating temperature.
4. A laminating arrangement according to claim 3 , wherein the maximum temperature is at least 35° C. higher than the operating temperature.
5. A laminating arrangement according to claim 1 , wherein a lag time is defined, and wherein, following a change in intensity of radiation emitted by the radiating element, no further change in intensity may occur until the lag time has expired.
6. A laminating arrangement according to claim 5 , wherein the lag time is at least substantially as long as a time taken for the laminating roller to complete a revolution at a rate of rotation used during laminating operations.
7. A laminating arrangement according to claim 5 , wherein the lag time is less than approximately a time taken for the laminating roller to form two complete revolutions at a rotation rate employed during laminating operations.
8. A laminating arrangement according to claim 1 , wherein the laminating roller is rotated whenever the radiating element is activated.
9. A laminating arrangement according to claim 1 , wherein, during an operation phase of the laminating arrangement, which follows the warm-up phase, the intensity of energy radiated from the radiating element is controlled, in accordance with the detected temperature of the surface of the laminating roller, to maintain the surface of the laminating roller at or near an operating temperature thereof.
10. A laminating arrangement according to claim 9 , wherein a plurality of high temperature bands are defined above the operating temperature, and wherein the intensity of radiation emitted by the radiating element is controlled in dependence of the high temperature band in which the detected temperature of the surface of the laminating roller falls.
11. A laminating arrangement according to claim 10 , wherein one or more low-temperature bands are defined below the operating temperature and wherein the intensity of the radiation emitted by the radiating element is controlled in accordance with the low temperature band in which the detected temperature of the surface of the laminating rollers falls.
12. A laminating arrangement according to claim 1 , wherein one or more fans are provided, the fans being positioned to direct a stream of air across the surface of the laminating roller to cool the laminating roller.
13. A laminating arrangement according to claim 12 , wherein the rate of rotation of the one or more fans is controlled in accordance with the detected temperature at the surface of the laminating roller.
14. A laminating arrangement according to claim 12 , configured so that, after passing over the surface of the laminating roller, air blown by the one or more fans is directed towards an exit point of the laminating roller.
15. (canceled)
16. A laminating arrangement according to claim 6 , wherein the lag time is less than approximately a time taken for the laminating roller to form two complete revolutions at the rotation rate employed during laminating operations.
17. A laminating arrangement according to claim 13 , configured so that, after passing over the surface of the laminating roller, air blown by the one or more fans is directed towards an exit point of the laminating roller.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0822638.3A GB2466061B (en) | 2008-12-11 | 2008-12-11 | Temperature control in a laminating device |
GB0822638.3 | 2008-12-11 | ||
PCT/GB2009/051680 WO2010067115A2 (en) | 2008-12-11 | 2009-12-10 | A laminating device |
Publications (1)
Publication Number | Publication Date |
---|---|
US20110226423A1 true US20110226423A1 (en) | 2011-09-22 |
Family
ID=40325962
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/130,927 Abandoned US20110226423A1 (en) | 2008-12-11 | 2009-12-10 | Laminating device |
US12/749,589 Active 2030-12-05 US8403015B2 (en) | 2008-12-11 | 2010-03-30 | Laminating device |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US12/749,589 Active 2030-12-05 US8403015B2 (en) | 2008-12-11 | 2010-03-30 | Laminating device |
Country Status (6)
Country | Link |
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US (2) | US20110226423A1 (en) |
EP (1) | EP2376285A2 (en) |
CN (1) | CN102317074A (en) |
GB (1) | GB2466061B (en) |
TW (1) | TW201029844A (en) |
WO (1) | WO2010067115A2 (en) |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2466060B (en) * | 2008-12-11 | 2013-09-04 | Acco Uk Ltd | A heating arrangement in a laminating apparatus |
GB2466061B (en) * | 2008-12-11 | 2013-09-04 | Acco Uk Ltd | Temperature control in a laminating device |
GB2482342A (en) * | 2010-07-30 | 2012-02-01 | Vestas Wind Sys As | Cooling of fibrous sheet for composite structure during machining |
CN104097380B (en) * | 2013-04-07 | 2016-11-23 | 致伸科技股份有限公司 | Thin slice laminating equipment |
GB2589133B (en) * | 2019-11-22 | 2023-01-04 | Vivid Laminating Tech Ltd | Laminating rollers |
TWI806144B (en) * | 2021-09-01 | 2023-06-21 | 臺灣塑膠工業股份有限公司 | Prepreg fiber fabric impregnation device and method thereof |
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- 2009-12-10 US US13/130,927 patent/US20110226423A1/en not_active Abandoned
- 2009-12-10 EP EP09771765A patent/EP2376285A2/en not_active Withdrawn
- 2009-12-10 WO PCT/GB2009/051680 patent/WO2010067115A2/en active Application Filing
- 2009-12-10 CN CN2009801565590A patent/CN102317074A/en active Pending
- 2009-12-11 TW TW098142570A patent/TW201029844A/en unknown
-
2010
- 2010-03-30 US US12/749,589 patent/US8403015B2/en active Active
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US4302276A (en) * | 1979-01-06 | 1981-11-24 | Karl Heinz Steigler | Machine for welding a moving web of material by means of a movable welding tool |
US4387000A (en) * | 1981-02-17 | 1983-06-07 | E. I. Du Pont De Nemours And Company | Laminating roll actuating crank mechanism |
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US7406993B2 (en) * | 2004-10-01 | 2008-08-05 | Transpacific Plasma Llc | Gear assembly of laminating apparatus |
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Also Published As
Publication number | Publication date |
---|---|
US8403015B2 (en) | 2013-03-26 |
CN102317074A (en) | 2012-01-11 |
GB2466061A (en) | 2010-06-16 |
GB0822638D0 (en) | 2009-01-21 |
GB2466061B (en) | 2013-09-04 |
WO2010067115A3 (en) | 2010-10-07 |
TW201029844A (en) | 2010-08-16 |
EP2376285A2 (en) | 2011-10-19 |
US20100181027A1 (en) | 2010-07-22 |
WO2010067115A2 (en) | 2010-06-17 |
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Legal Events
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AS | Assignment |
Owner name: ACCO UK LIMITED, UNITED KINGDOM Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:BRADLEY, SAMUEL JAMES;REEL/FRAME:026333/0170 Effective date: 20110523 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |