CN100346979C - 实现导热涂层操作温度的方法以及导热涂层装置 - Google Patents

实现导热涂层操作温度的方法以及导热涂层装置 Download PDF

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CN100346979C
CN100346979C CNB038193760A CN03819376A CN100346979C CN 100346979 C CN100346979 C CN 100346979C CN B038193760 A CNB038193760 A CN B038193760A CN 03819376 A CN03819376 A CN 03819376A CN 100346979 C CN100346979 C CN 100346979C
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M·博莱达
D·J·阿卡罗
J·哈瓦德
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Abstract

用于导热涂层技术的方法和装置。对于整个状态(405-421)进行预计。进行熔凝器(305)的多级预热,可以取消导热涂层期间的主动加热。热波产生积累的熔凝器热量,该热量足以保持整个导热涂层循环所需的大致恒定的熔凝器温度。

Description

实现导热涂层操作温度的方法以及导热涂层装置
技术领域
本发明总体涉及导热涂层(TTO)技术。
背景技术
在导热涂层技术中,薄膜粘接到文件上以便提供耐用性和光泽。图1(现有技术)表示通用TTO设备100。如本领域所公知那样自动文件供应器(ADF)101供应预先印刷的文件(通过如此标示的水平线表示)到加压辊103和加热辊105之间的辊隙上。来自薄膜供应卷筒109的涂层薄膜107通过相同的辊隙。薄膜107通常是导热粘合剂层压材料,通过加热辊105激励,以便形成文件印刷表面的光亮涂层。在通过辊隙之后,辊隙下游的剥离杆装置111将薄膜107的背衬与现在涂层的文件113分离。薄膜卷取卷筒115接收薄膜背衬材料。
控制导热涂层技术的一个非常精密的参数是辊隙内的薄膜和介质界面温度。为了适当进行涂层操作,粘合剂涂层需要融化,使其流动地填充文件介质内的孔,在最终涂层的文件产品上形成涂层。此外,为了获得接受的产量,例如每分钟三页(ppm),该过程必须相对快速地进行。此外,当正在涂层的文件在辊隙中与薄膜配合时,形成相对大的热沉。通常,在导热涂层操作期间监测温度并通过在检测到最低可接受温度时添加大量热量来相应地控制该过程。该方法造成很大的温度起伏。同样还需要相对大功率和快速反应的热源。通常,反应系统必须采用更加昂贵的产品构造,例如提供另外的加热元件、传感器和控制器,以便减小热质量。另外,需要稳定地连续操作以便实现稳定性。
发明内容
本发明提供在特定温度范围内进行涂层操作以便通过对于涂层操作过程中的各种情况进行预计来优化产品质量和产量的方法和装置。
以上概括不局限于所有方面、目的、优点和特征所列举的内容,也不对于本发明的范围作出限制。该概括只按照37C.F.R.1.73和M.P.E.P.608.01(d)条例公知于众,并且特别是与本发明相关的特定领域内的对于本发明性质有兴趣的人们在将来检索中便于理解本专利。
附图说明
图1(现有技术)示意表示TTO设备和方法的立视图;
图2示意表示按照本发明示例性实施例的涂层薄膜的立视图;
图3示意表示按照本发明示例性实施例的加压辊和加热辊构造的立视图;
图4是表示按照本发明示例性实施例的过程的流程图。
相同的参考标号在附图中表示相同的部件。除非特别说明,此说明书中所参考的附图应该理解为没有按照比例绘制。
具体实施方式
现在参考图2,薄膜107具有例如聚酯材料(PET)的背衬或“载带”201。在通过剥离杆111从文件113上剥离之后,该背衬201终止于辊隙下游的卷取卷筒115。剥离层203(本领域有时称为“分离器”)靠近载带201,该层的示例性材料是棕榈蜡。可转移涂层205靠近剥离层203。可转移涂层205包括彩色涂层207和粘合剂涂层209的层压制品。彩色涂层例如是为涂层文件113提供光泽、持久性和耐用性的上光树脂。粘合剂涂层209例如是在辊隙内进行导热涂层过程中将彩色涂层粘接到介质上的丙烯酸。最好是,粘合剂涂层209具有大致90℃的融化温度。
将涂层207、209施加在文件上涉及控制加压辊103和加热辊105之间辊隙内的多个物理变量,以便融化薄膜107的剥离层203和粘合剂涂层209,造成涂层207、209转移到介质上,同时剥离通过剥离杆111和卷取卷筒115去除的载带201。
按照本发明的实施例,图3示意表示辊隙307处进行接触的加压辊303(与图1元件103类似)和加热辊305(与图1元件105类似)的立视图。如标示“熔凝器运动”的箭头表示,加热辊305是可运动的组件,有选择地与加压辊303接合,以便根据需要形成辊隙307。例如微处理器或专用集成电路(ASIC)印刷电路板的控制器系统309进行编程以便控制导热涂层操作。
加压辊303包括或至少具有由例如硅酮橡胶的柔性材料制成的外表面。该柔性材料具有相对高的耐热性,也就是说显著大于辊隙307内达到的导热涂层操作融化温度。
加热辊305是包括圆筒311的组件,圆筒311具有壁,壁由例如铝的金属或例如铝的具有快速导热能力的其它材料形成,该壁通过外箍缠绕,外箍有时称为“外皮”313,同样由例如硅酮橡胶的具有相对高的耐热性的柔性材料制成。在圆筒311内是例如卤素灯泡的加热元件315,其具有在操作过程中通过控制器309确定的开和关状态。注意到加热元件315还可具有连续范围的功率和温度设置,或者通过公知方式的脉冲宽度调制(PWM)技术控制。加热辊305组件还在此后称为“熔凝器”305。例如热敏电阻的温度传感器317保持跟踪外皮313的温度“T”,以用于控制器309。
在示例性操作中,如图4(同时参考图2或3以便于理解)所示,采用预计温度控制器。采用熔凝器305的三级加热或预热循环,预计激励粘合剂涂层209和剥离层203所需温度和进行导热涂层时造成温度下降的辊隙热沉状态。首先两级的加热使得熔凝器305快速升至所需基本融化温度,而没有过量,由此减小使用者的等待时间,同时防止设备过热。第三级预计辊隙热沉状态。
辊隙内的融化温度必须不太高,否则载带201(图2)过于膨胀,在涂层文件113的表面上产生皱纹。如果温度过高,还可产生烟雾状的释放污染物。另一方面,融化温度必须足够高以形成一个导热速度,该速度对于所需剥离温度、针对产量的涂层过程(即文件通过辊隙307的速度)以及薄膜107和文件介质之间的粘接过程的特性来说是足够的。
因此,熔凝器305提供三级加热循环,该循环对于辊隙307内进行涂层时的温度降低进行预计。三级加热循环在没有接合辊子303的情况下进行,即熔凝器305在升高(见箭头“熔凝器运动”)位置,还没有与加压辊303接触,有利地防止对于剥离层203(图2,以及图4的401)的任何损坏。注意到已经发现与辊子103、105一直接合的方法相比,这种方法提供更快的加热时间。虽然可以选择另一触发的方法,第一级可以在ADF101开始供应印刷文件但在文件导前边缘到达辊隙317之前触发。外皮温度“Ts”通过温度传感器317确定(见图4,403)。根据薄膜107的特定应用性能和由ADF101所供应的将要涂层的介质类型,将知道用于最佳涂层的优选融化温度“Tt”。第一预热目标温度与融化温度相关。该关系将作为应用标准并可以通过经验确定。
外皮温度和第一预热目标温度之间的温度差“Gt”作为预定值,使得虽然当前外皮温度和目标温度之间的差值大于预定温度差,加热器315连续接通(见图4,405,是路径,407)。例如,继续这种恒定加热过程,而加热辊的外皮温度大于第一预热目标温度以下的大约70%(其中,70%是针对特定应用而通过经验确定的,并可以根据熔凝器辊的构造和材料变化)。
当温度差到达预定值并且开始超过预定值时,加热器315进入脉冲模式,减小外皮温度变化的增量速度增益(见图4,405,否路径,409)。这包括第二级加热循环。当外皮温度接近第一预热目标温度时,加热器315的脉冲接通-断开的占空因数减小(见图4,411,否路径,413,415)。当外皮温度到达目标值并将保持目标值长达预定时间周期“Tc”(例如四秒)时,第二级完成。当外皮温度至少处于目标值时所选择的预定时间周期将取决于介质薄膜融化性能和特定应用的介质整体参数。关键是实现稳定的外皮温度(见图4,417,否路径,413)。注意到可以交替地减小热量梯度,而不是进行脉冲接通断开加热,但是确信采用脉冲可以实现更好的结果。
一旦实现稳定的外皮温度(图4,是路径),加热器315元件再次连续接通(见图4,419)。这是第三级加热循环。加热器315保持接通直到外皮温度升高并超过第一预热目标温度预定的量,例如5度(见图4,421,否路径)。再者,特定的过量将取决于介质薄膜融化特性和特定应用的整体参数。已经发现阶段3中的过热在加热辊305内产生热波,在过热期间内热波缓慢到达外箍313外表面。这将外箍313外表面保持在最佳融化温度“Tt”的可接受范围内。一旦实现第一预热目标温度的过量温度,加热器315将断开(见图4,423)。
辊子303、305通过降低熔凝器组件来接合,以便和加压辊303形成辊隙307(见图3,标示“熔凝器运动”的箭头以及图4,425)。
来自ADF101的文件的导前边缘和来自供应卷筒109的薄膜107现在在辊隙307相遇。热波产生积累热量,该热量足以保持整个涂层操作所需的大致恒定的外皮温度(即融化温度范围“Tt±Δ”),例如大约165℃+5或-10度。在此实施例中,加热器315在整个涂层操作期间保持断开。但是注意到在任何特定实施例中,熔凝器辊子外皮厚度可以是确定的,或者是纸张长度、产量或类似参数的至少一个因素,如本领域普通技术人员所知;热能力中的损失将需要一个接通循环,大多数可能在实际涂层操作的开始阶段。
在另一示例性实施例中,可以在涂层阶段内启动加热器一段时间,并随后返回到受控的等待温度。
因此,对于本发明所描述的示例性实施例的应用来说,通过对于涂层操作参数的需要进行预计,提供整个导热涂层过程中的温度均匀性。换言之,对于以下特定应用,即介质的特性是公知的、层压薄膜的特性是公知的以及通过加热辊和加压辊之间辊隙的产品速度是公知的,可以采用加热辊的预计三级循环,以便在加热元件断开的涂层操作中在辊隙内产生大致恒定的热交换。
出于说明和解释的目的,提供示例性和优选实施例的以上描述。不打算将本发明限制在所披露的准确形式或示例性实施例中。显然是,本领域普通技术人员将明白许多变型和改型。类似地,许多描述的过程步骤可以互换或与其它步骤组合,以便实现相同的结果。选择和描述每个实施例以便最好地描述本发明的原理及其最佳实施方式,由此本领域普通技术人员将理解不同的实施例和不同的变型可适用于特定使用或所打算的应用。虽然此说明书针对现有技术进行说明,同样必须认识到本领域可以具有许多进步;因此,可以考虑进行进一步的改进并适用于这种进步。因此,通过以上说明不打算限制要求保护的本发明的范围,该说明包括误差、结构尺寸、特定操作状态、工程参数等,并在应用和改进之间变化,或者在应用时对于现有技术进行变化,而没有隐含其中。所打算的是本发明的范围通过所附权利要求及其等同物来限定。除非指明之外,单数的元件不打算表示“一个和只有一个”,而是指的是“一个或多个”。此外,不管说明书中的元件、部件或方法步骤在以下权利要求中得到明确的说明,该元件、部件或方法步骤不打算专用于公开。这里除非使用“用于…装置”的词语来明确表示元件,这里权利要求中的元件不认为遵守35U.S.C.条例的sec112,第六段,并且除非使用“包括…步骤”的词语来明确表示一个或多个步骤,这里的步骤不认为遵守这些条例。

Claims (8)

1.一种实现导热涂层操作温度的方法,该方法的特征在于:
使用内部热源(315),预热(403-417)加热装置,以便在其外表面上实现大致恒定的目标温度;
当稳定所述目标温度时,将所述加热装置过热(419-421)到高于所述目标温度的温度;
断开所述源(423);以及
将所述加热装置和加压装置接合(425-427)以便进行直接导热涂层操作;
其中,所述过热在所述加热装置内产生热波,使得积累的热量足以保持所述涂层操作温度,以便进行整个所述导热涂层操作。
2.如权利要求1所述的方法,预热的特征还在于:
接通所述源并将所述外表面的温度升高到小于所述目标温度的预定值(405);
脉动(409)接通和断开所述源,同时将所述外表面的所述温度从所述预定值升高到大致所述目标温度。
3.一种导热涂层装置,包括:
加压辊(303);
根据需要接合所述加压辊的可选择定位的加热辊(305);
所述加热辊内部的加热元件(315);以及
控制加热辊位置和所述加热元件的控制器(309),其中在对于输入所述辊隙的文件进行涂层之前并且在加热辊的表面温度已经稳定使得在所述导热涂层操作期间所述加热元件断开之后,所述加热辊进行定位以便和所述加热辊形成用于所述导热涂层的辊隙。
4.如权利要求3所述的装置,包括:
为所述控制器(309)提供表示当前加热辊表面温度的信号的监测器(317)。
5.如权利要求3所述的装置,包括:
所述控制器(309)进行编程以便为所述加热元件提供多个有选择的加热循环。
6.如权利要求5所述的装置,所述循环包括至少一个恒定热循环和可变热循环。
7.如权利要求6所述的装置,其特征在于,所述可变热循环包括加热元件的可变脉冲占空循环。
8.如权利要求4所述的装置,其特征在于,加热辊的所述表面温度通过分级预热操作经由第一加热阶段、第二加热阶段和第三加热阶段稳定,在第一加热阶段中所述当前温度相对快速升高到第一温度,在第二加热阶段中所述当前温度相对缓慢地升高到第二温度,并且在第三加热阶段中所述当前温度相对快速地升高到超过最佳导热涂层融化温度预定值的第三温度。
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