Chiller Box Cooling for Non-Tacky Waxed Web Coating
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Solution Overview
Problem
Existing methods for coating flexible sheet-like substrates with waxy materials face challenges such as tackiness, leading to handling difficulties and machinery fouling, which result in process interruptions and downtime during the production of disposable absorbent articles like tampons.
Innovation Solution
A process involving the application of a waxy composition to a flexible substrate, followed by cooling using a chiller with a liquefied gas source at extremely low temperatures, forming a stable liquid mixture that solidifies without flaking off, enabling efficient and trouble-free manufacturing of robust, flexible sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If waxy composition is applied to the substrate, then the coating provides robust and flexible properties, but the waxy material becomes tacky and causes handling difficulties and machinery fouling
Solution Approach 1:
The patent applies cold gas at extremely low temperatures (e.g., liquid nitrogen at -196°C or liquid carbon dioxide at -78.5°C) to change the thermal state of the waxy coating from tacky to solid, thereby improving handling ease without compromising coating robustness
Solution Approach 2:
The patent utilizes phase transition of the waxy material from a tacky state to a solid state through rapid cooling with cold gas, eliminating handling difficulties and machinery fouling while maintaining the coating's protective properties
2Strength
If waxy composition is applied to the substrate, then the coating provides robust properties, but the tacky waxy material causes process interruptions and downtime
Solution Approach 1:
The patent changes the temperature parameter of the waxy coating through application of cold gas, transforming it from a problematic tacky state to a non-tacky solid state, thereby preventing process interruptions and maintaining high production efficiency
Solution Approach 2:
The patent converts the harmful tackiness of the waxy material into a beneficial solid state through controlled cooling, transforming a production problem into a solution that maintains both coating robustness and production efficiency
3Stability of the object's composition
If cold gas is used to cool the waxy web, then the coating solidifies without flaking, but the machinery and substrate must withstand extreme temperatures
Solution Approach 1:
The patent uses cold gas (liquid nitrogen or liquid carbon dioxide) as an intermediary cooling medium that can be applied remotely to the moving web, allowing the waxy coating to solidify without direct contact between the substrate and the cold gas source, thereby minimizing thermal shock to the machinery
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 process results in a robust, flexible coated substrate that prevents coating loss during processing, allowing for high-speed and economic production of articles intended for contact with human body surfaces, such as tampons, without significant downtime.
Implementation Method 1
cooling using a chiller with a liquefied gas source at extremely low temperatures
Implementation Method 2
forming a stable liquid mixture that solidifies without flaking off
Data Source
AI summary
A process for manufacturing robust, flexible sheet-like material, includes the steps of a) applying a waxy composition to the web to form a waxed web; b) leading the waxed web via at least one roller to a chiller; c) cooling the waxed web; and d) leading the waxed web to a collection station for collecting the waxed web for further processing. The waxy composition comprises about 10-60 wt-% of a waxy compound and about 90-40 wt-% of a diluent. The waxy compound is selected from the group consisting of A) monoesters of a polyhydric aliphatic alcohol and a fatty acid; B) diesters of a polyhydric aliphatic alcohol and a fatty acid; and C) mixtures of said monoesters and diesters. The coating forms a stable liquid mixture at a temperature between about 35° C. and about 100° C., has a liquefaction temperature of at least about 30° C., and has a contact angle with a flat surface of the substrate of less than about 35° when measured at a temperature of 60° C.