Abstract
There is provided a laminating system (30) comprising a laminating module (200) and a transportation module (100) wherein the transportation module (100) is arranged to automatically drive the laminating module (200) over a surface (10) to be laminated. Here the surface (10) to be laminated is large and maintained substantially stationary. The transportation module (100) includes a retaining means and a drive means. The retaining means resists movement of the laminating module (200) relative to the surface (10) except when the laminating module is driven by the drive means. The laminating module (200) includes an unwind unit (210) adapted to receive a roll of laminate (20). The laminate (20) comprises an adhesive film and first release layer. The unwind unit (210) is adapted to allow the laminate to be unwound from the roll. A first release layer discard unit is provided. The first release layer discard unit is adapted to remove the first release layer from the laminate. The laminating module (200) includes a first pressing unit (240). The first pressing unit (240) is adapted to press the film onto the surface (10). Here, the retaining means is adapted to resist a pressing force applied by the first pressing unit (240) and acting to move the laminating module (200) away from the surface. As the transportation module (100) automatically drives the laminating module (200) over the surface, the pressing unit (240) presses the film to the surface.
Claims
1. A laminating system (30) comprising a laminating module (200) and a transportation module (100) wherein the transportation module (100) is arranged to drive the laminating module (200) over a surface (10) to be laminated; wherein the transportation module (100) includes a retaining means and a drive means, wherein the retaining means generates a magnetic force and the magnetic force acts to retain the laminating module (200) relative to the surface (10) so as to resist movement of the laminating module (200) relative to the surface (10) except when urged to move in a laminating direction by the drive means; and the laminating module (200) comprising an unwind unit (210) adapted to receive a roll of laminate (20) and a first pressing unit (240) arranged to press the laminate (20) against the surface (10) to be laminated; wherein the transportation module (100) comprises magnetic wheels (136), the magnetic wheels being arranged to be driven to rotate to both act as the driving means and the retaining means.
2. The laminating system (30) of claim 1, wherein the laminating module (200) includes a second pressing unit (250), spaced from the first pressing unit (240) in the laminating direction.
3. The laminating system (30) of any preceding claim wherein each pressing unit (240, 250) comprises a pressing surface (242), wherein the pressing unit is arranged to press the pressing surface against the surface (10) being laminated.
4. The laminating system (30) of claim 3 wherein the pressing surface (242) has a hardness selected so that the pressing surface deforms against the surface (10) being laminated.
5. The laminating system (30) of claim 3 or claim 4, wherein each pressing unit (240, 250) includes an actuator (246) to apply a pressing force to the pressing surface (10).
6. The laminating system (30) of any of claims 2 to 5, wherein the laminating module (200) comprise heating means, the heating means forming a first zone (262) arranged to pre-heat the area in front of the first pressing unit (240) relative to the laminating direction, and a second zone (264) to heat the laminate between the first and second pressing units and, optionally, a third zone (266) arranged to heat the laminate behind the second pressing unit (250) relative to the laminating direction.
7. The laminating system (30) of any preceding claim, wherein the laminating module (200) includes a moveable guide arranged to apply a nip against a pressing surface of the first pressing unit (240), the moveable guide being arranged to move simultaneously with the pressing surface to transfer the nip from one side of the pressing unit to another relative to the direction of laminating.
8. A method of laminating a surface (10) using a laminating system (30) according to any preceding claim, the method comprising; arranging a transportation module (100) on the surface (10) to be laminated using a retaining means of the transportation module to anchor the transportation module by magnetic interaction of the retaining means and surface, causing the transportation module (100) to drive a laminating module (200) relative to the surface in a laminating direction whilst restricting relative movement in other directions by rotating magnetic wheels of the transportation module; completing a first laminating step by pressing a laminate against the surface whilst causing the relative movement of the laminating module and surface; and repositioning the transportation module to complete a second laminating step.
9. The method of claim 8, wherein the laminate comprises a thermoplastic substrate and a fouling release and/or anti-fouling coating layer applied thereto.
10. A laminating module (100) comprising: an unwind unit (210) adapted to receive a roll of laminate (20); a pressing station arranged to press the laminate (20) against the surface (10) to be laminated; and a heating means adapted to apply heat during a laminating process; characterised in that the pressing station comprises a first pressing unit (240) and a second pressing unit (250) spaced from the first pressing unit (240); and the heating means comprises a first zone (262) to pre-heat an area forward of the first pressing unit (240); a second zone (264) to heat the laminate pressed to the surface by the first pressing unit (240) forward of the second pressing unit (250); and a third zone (266) arranged to heat the laminate behind the second pressing unit (250) relative to the laminating direction.
11. A laminating system comprising the laminating module (200) of claim 10 and a transportation module (100), wherein the transportation module (100) is arranged to drive the laminating module (200) over a surface (10) to be laminated; and the transportation module (100) includes a retaining means and a drive means, the retaining means interacting with the surface so as to resist movement of the laminating module (200) relative to the surface (10) except when urged to move in a laminating direction by the drive means.
12. A method of laminating comprising applying a pre-heat before pressing a laminate (20) to a surface (10) using a first pressing unit (240), applying a second heat to heat the laminate pressed to the surface by the first pressing unit (240) and subsequently using a second pressing unit (250) to further press the laminate (20) against the surface (10).
13. A laminating module (100) comprising: an unwind unit (210) adapted to receive a roll of laminate (20); a pressing station arranged to press the laminate (20) against the surface (10) to be laminated and comprising a first pressing unit; and a laminate delivery system including a moveable guide arranged to apply a nip against a pressing surface of the first pressing unit (240), the moveable guide being arranged to move simultaneously with the pressing surface to transfer the nip from one side of the pressing unit to another relative to the direction of laminating.
14. A laminating system comprising the laminating module (200) of claim 13 and a transportation module (100), wherein the transportation module (100) is arranged to drive the laminating module (200) over a surface (10) to be laminated; and the transportation module (100) includes a retaining means and a drive means, the retaining means interacting with the surface so as to resist movement of the laminating module (200) relative to the surface (10) except when urged to move in a laminating direction by the drive means.
15. A method of laminating comprising: feeding a laminate between a guide and pressing surface of a first pressing unit and moving the guide towards the pressing surface to nip the laminate against the pressing surface; moving the guide simultaneously with the pressing unit to transfer the nip from one side of the pressing unit to another relative to the direction of laminating.
Description
[0030] For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:
[0031] FIG. 1 shows a laminated surface having surface irregularities;
[0032] FIG. 2 shows a void created when laminating a surface irregularity;
[0033] FIG. 3 is a schematic perspective view of a laminating system of an exemplary embodiment;
[0034] FIG. 4 shows views of a frame for use with the exemplary embodiment of FIG. 3, wherein FIG. 4a is a plan view and FIG. 4b is a side view;
[0035] FIG. 5 shows a schematic perspective view of a corner of the frame of FIG. 4 in more detail including retaining means;
[0036] FIG. 6 shows an end of the frame of FIG. 4 in more detail including a drive means;
[0037] FIG. 7 shows a schematic perspective view of an alternative embodiment of a laminating system;
[0038] FIG. 8 shows a perspective view of a laminating module of an exemplary embodiment;
[0039] FIG. 9 shows a perspective view of the laminating module of FIG. 8 from the other side and with a protective cover removed;
[0040] FIG. 10 shows a schematic side cross-sectional view of the exemplary laminating module;
[0041] FIG. 11 shows a cross-sectional perspective view of a region of the laminating module of FIG. 8 including a peeling knife;
[0042] FIG. 12 shows a perspective view of a pressing roller according to an exemplary embodiment;
[0043] FIG. 13 shows an perspective view of an exemplary heating element; and
[0044] FIG. 14 shows schematic views detailing an exemplary laminating process.
[0045] Referring to FIG. 1, a surface 10 is shown with a laminated stripe, wherein the laminated stripe is a laminate 20 having been bonded to the surface 10 during a laminating process. The surface 10 is shown as having surface irregularities 12. The surface irregularities are typical of weld seams and rivets as found on the hull of a ship. The laminating process needs to be completed after the ship has been constructed and the surface is therefore large with access to only one side. Moreover, the surface is typically vertically orientated. Here, vertically orientated or vertical surface includes surfaces arranged in a generally upstanding direction, including sloped surfaces. The exemplary embodiments provide a system and method for automatically laminating the surface in a series of adjacent laminating steps and in particular to a system and method for reducing the voids around surface irregularities.
[0046] Referring to FIG. 3, a laminating system 30 is shown. The laminating system 30 comprises a transportation module 100 and a laminating module 200. The transportation module is arranged to drive the laminating module over the surface 10 to complete a lamination step and to form a stripe of lamination on the surface. Here, because the surface is larger than the laminating system, the laminating stripe covers only a portion of the surface. The laminating system is then re-positioned, before second and subsequent laminating steps are completed to lay adjacent stripes of laminate to cover the surface 10. The transportation module 100 includes a drive means and a retaining means. The retaining means is adapted to resist relative movement of the laminating module and surface. The drive means is arranged to drive the laminating module over the surface, wherein the retaining means does not prevent the relative movement of the laminating module and surface caused by the drive means.
[0047] In FIG. 3, the transportation module 100 is suitably shown as a guiding frame 110. The guiding frame is arranged to carry the laminating module 200 as a shuttle. The laminating module is therefore elongate in the laminating direction and the length of the frame 110 delimits a length of each laminating stripe before the transportation module 100 is repositioned. Referring to FIG. 4, the frame is generally rectangular having rails 112 along each long side upon which the shuttle travels. Lifting hooks 114 or other transportation fixings are formed fixed to the frame to enable the frame to be moved and repositioned. The frame 110 is fixed to the surface by the retaining means. The retaining means may be any suitable fixing method to secure the frame to the surface. As shown in FIG. 5, suitably the retaining means are a plurality of mounting feet 120. The frame is shown in FIG. 4b as having four mounting feet, one on each corner of the frame 110. However, it will be appreciated that the number of mounting feet is determined by the support required by the frame. More feet may therefore be provided, particularly along the length to retain the rails more directly. The feet 120 may suitably be extendible so that the feet can be adjusted to compensate for surface flatness. In the exemplary embodiments, the feet 120 are temporarily fixed to the surface through magnetic attraction. As shown in FIG. 5, the distal ends of the feet 120 may therefore include a magnet such as an electro magnet. The elector magnetic forces clamp the frame 110 to a ferrous surface and provide a stationary guiding frame for the laminating module.
[0048] As shown in FIG. 6, the drive means is suitably shown as an actuator for moving the laminating module mounted as a shuttle relative to the frame. Here, the shuttle runs on the rails 112 of the frame and the actuator acts between the frame and shuttle. In FIG. 6, the actuator is shown as a motor 130 driving a timing belt 132 to which the shuttle is attached. However, other actuators such as pistons or gears would also achieve the required driving force. The speed at which the shuttle is driven along the frame is a factor of the laminating process and can be controlled by controlling the actuator. Typically the shuttle might be driven along the frame between 1.2 m/min and 8.0 m/min.
[0049] FIG. 7 shows an alternative exemplary embodiment of a laminating system 30. Here, the laminating module is fixed relative to a frame 110 of a transportation module 100. The transportation module 100 includes drive means to drive the laminating module over the surface to complete a laminating step and retaining means to restrain the laminating module from moving relative to the surface. In this embodiment, the retaining means and driving means are provided integrally as magnetic rollers 136. The magnetic rollers secure to a ferrous surface through magnetic attraction. The magnetic rollers are driven about their axis to roll over the surface whilst maintaining the magnetic attraction there between whilst restricting other relative movement. The exemplary embodiment is shown with four magnetic rollers. However any number of magnetic rollers is envisaged to provide a stable platform for the laminating module. Furthermore, the magnetic rollers are shown as magnetic wheels symmetrically arranged, but other configurations are envisaged and the rollers 136 may be arranged within the laminating stripe or to one side or a combination thereof.
[0050] The laminating module 200 presses a laminate to the surface to complete the laminating step. Referring to FIG. 8, in the exemplary embodiments, the laminating module 200 includes an unwind roller 210. The unwind roller 210 receives a roll of laminate 20. The unwind roller 210 is mounted to a frame 202 of the laminating module in a rotatable configuration. Here the unwind roller rotates about its central axis to unwind the laminate. The laminate may include lower and/or upper release layers. Optional release layer discard units are therefor provided to remove the discard layers prior to the lamination. As shown in FIG. 8, a first release layer discard unit 220 is provided. As shown, suitably, the discard unit is an empty shaft that is mounted to the frame 202 and able to rotate thereto. The lower release layer is separated from the laminate and attached to the shaft. The shaft is caused to rotate to wind-up the release layer as the laminate is laid. A second release layer discard unit 222 is provided in a similar manner to wind-up the upper release layer. As is shown in FIG. 9, the shafts of each release layer discard unit (not shown) may be driven by a motor and timing belt 224 to rotate and brakes and other tensioning means may be applied as is known in the art to maintain a correct tension of the release layers.
[0051] FIG. 10 shows the guide path of a laminating module according to an exemplary embodiment. Here the laminate comprises a self-adhesive laminate 22 and upper 24 and lower 26 release layers. The upper release layer is pulled directly from the laminate roll. The self-adhesive laminate 22 and lower release layer protecting the self-adhesive is guided by laminate guide means towards pressing stations that press the laminate to the surface. Prior to the first pressing operation, the lower release layer 26 is peeled from the self-adhesive laminate. Here, suitably a peeling knife 204 is provided. As shown in FIG. 11, the peeling knife 202 comprises a beam extending across the laminate 20 and forming a bevelled edge against which the lower release layer is arranged to bear. The bevelled edge acts to pull the lower release layer against the direction of movement of the laminate. The self-adhesive laminate includes a thermoplastic substrate to which the self-adhesive layer and other coatings and surface preparations are applied. The thermoplastic substrate is suitably a Polypropylene sheet. Advantageously, the thermoplastic substrate can be heat treated to soften and more easily deform over surface irregularities.
[0052] In the exemplary embodiments, the laminating module 200 includes a pressing station to press the laminate on to the surface. The pressing station includes a pressing surface over which the laminate is passed. In the exemplary embodiments, the pressing surface is shown as a first and second pressing rollers 240, 250. Whilst one roller is able to laminate flat surfaces it has been found that the second roller acts to reduce void formation around surface irregularities as compared to a single roller. The second pressing roller 250 is spaced behind the first pressing roller 240 in the direction of lamination. An automatic feeding boom is provided in the exemplary embodiments to nip the laminate against the pressing surface. By moving the boom in registration with the pressing surface, the nip can be moved underneath the pressing surface ready for a lamination step. The nip can be released to carry out the laminating step before the automatic feeding boom is reset ready for the next laminating step.
[0053] Each pressing roller 240, 250 can be explained with reference to FIG. 12. The pressing roller 240 includes a pressing surface 242 formed as a continuous surface that is arranged as a roller to rotate and press the laminate to the surface. A pressing force is applied to the pressing surface 242. In the exemplary embodiments, the pressing force is applied by an actuator that acts between a frame 202 of the laminating module and rotational shaft 244 of the pressing surface to move the pressing surface towards and away from the frame. The actuator may have a large range of travel so as to advantageously withdraw the pressing surface during transportation. The actuator is arranged to apply a set pressing force and the pressing force can be controlled by controlling the actuator. As shown in FIG. 12, in the exemplary embodiments, a first 246 and second 248 actuator is provided at either side of the shaft 244.
[0054] In the exemplary embodiments the pressing surface 242 of each pressing unit is deformable. That is, the hardness of the pressing surface is selected so as to deform under the pressing force. In the exemplary embodiments comprising a pressing roller, the pressing surface hardness is selected to deform and flatten. Suitably, the pressing surface is formed from an open cell structure, as it has been found that an open cell material more readily deforms in both the axial direction and laminating direction. The open cell structure may form cells in the range of 0.5 mm and 0.2 mm in diameter.
[0055] Referring back to FIG. 10, the laminating module of the exemplary embodiments includes heating means. The hearing means 260 heats the laminate and/or surface being laminated. In the exemplary embodiments, the heating means is formed into three zones. A first zone preheats the surface being laminated and preheats the laminate prior to the first pressing unit. Here a first strip heater 262 is provided across the width of the laminate. The strip heater 262 is angled to the surface being laminated so as to radiate heat directly to both the surface and laminate. Here, the laminate is guided towards the first pressing unit in a direction substantially perpendicular to the surface. Other configurations are envisaged and may require the first strip heater to be formed in two modules with each module directing heat to the surface and laminate respectively. The second zone is provided between the first and second pressing units. Again the zone may be formed by a second strip heater 264. The second strip heater extends across the width of the laminate and heats the laminate to a temperature where the laminate becomes weak and flexible in preparation for the second pressing step. The third zone is to trail the second pressing unit. The third zone may be formed from a third strip heater arranged to heat the laminate to stress relieving temperatures.
[0056] FIG. 13 shows an exemplary strip heater used as strip heaters 262, 264, 266. It will be appreciated that the strip heaters can be controlled to precisely control the temperature of each zone. Glass shortwave heating elements are used to achieve the exemplary heating characteristics.
[0057] The exemplary laminating process will now be described with reference to FIG. 14. A laminate roll is loaded onto unwind unit 210. Empty shafts are loaded onto release layer discharge units 220, 222. The top release layer is peeled from the laminate 20 and fixed to the empty shaft of discharge unit 222. The laminate is guide through the laminating module to the peeling knife 204. A cutting knife may also be provided at the peeling knife to cut through the self-adhesive laminate but suitably not the lower release layer. The lower release layer is peeled from the self-adhesive laminate and fixed to the shaft of the discard unit 220. The lower discard layer acts against the peeling knife to travel backwards against the direction of travel of the self-adhesive laminate. The self-adhesive laminate is fed between the boom and pressing surface and the nip applied. The first pressing roller and boom are moved in registration about the axis of the roller. The self-adhesive laminate is therefore fed automatically underneath the pressing roller. The transportation unit is arranged on the surface to be laminated. The first and second pressing units are lowered to press the pressing surfaces against the surface. The nip can then be removed from the pressing roller. The transportation unit is operated to drive the laminating module over the surface. When the laminating module completes the laminating stripe, the self-adhesive laminate is cut. The first and second pressing units are raised, the nip reapplied and the transportation unit re-positioned. A second and subsequent laminating step can then be completed.
[0058] Although certain embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.
