Composite Transparent Board Crystallization Prevention
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Solution Overview
Problem
Conventional PET transparent boards are made of single materials, limiting optimization across layers and prone to crystallizing and whitening during the forming process.
Innovation Solution
A composite transparent board is produced using a method that feeds three different resins into extruders to form a composite transparent film, which is then formed into a board using specific temperature-controlled forming wheels, preventing crystallization and whitening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional single-material PET transparent board is used, then the manufacturing process is simple, but the board exhibits crystallizing and whitening phenomena during the forming process
Solution Approach 1:
The patent applies composite materials by combining three different resin types (first resin: Tairilin 3824/3842/390A/P115/663G/SKYGREEN S2008, second resin: Tairilin 3760/3842, third resin: Tairilin 3760/3842/380R/384R) in specific layers to prevent crystallization and whitening while maintaining manufacturing feasibility through a systematic forming process with controlled temperatures
2Reliability
If a composite transparent board with multiple resin layers is produced, then the crystallizing and whitening phenomenon is prevented, but the manufacturing process complexity increases
Solution Approach 1:
The patent segments the transparent board into three distinct layers, each with specific resin compositions and thickness ratios (first layer: 40-70%, second layer: 15-40%, third layer: 10-20%), allowing independent optimization of each layer's properties while managing overall process complexity through systematic temperature control
Solution Approach 2:
The patent employs parameter changes by precisely controlling the temperatures of forming wheels (first forming wheel: 18-25°C, second forming wheel: 18-25°C, third forming wheel: 35-58°C) and resin intrinsic viscosities (0.63-1.1 dl/g) to achieve optimal forming results and prevent defects
3Productivity
If the forming wheels are operated at high temperatures to improve forming speed, then productivity increases, but the board surface quality deteriorates due to crystallization
Solution Approach 1:
The patent applies parameter changes by implementing a multi-stage temperature control system where the first and second forming wheels operate at lower temperatures (18-25°C) to prevent crystallization, while the third forming wheel uses higher temperatures (35-58°C) for final shaping, achieving both high productivity and superior surface quality
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 composite transparent board achieves a haze range of 0.75% to 4% and a total light transmittance range of 86% to 91.5%, effectively preventing the crystallizing and whitening phenomenon.
Implementation Method 1
The forming step is implemented by sequentially passing the composite transparent film through a first forming wheel, a second forming wheel, and a third forming wheel to form a composite transparent board. An absolute value of a difference between a temperature of the first forming wheel and a temperature of the second forming wheel is less than or equal to 5° C., and a ratio between a temperature of the third forming wheel and the temperature of the first forming wheel or the temperature of the second forming wheel is within a range from 1.8 to 3.5.
Data Source
AI summary
A composite transparent board and method for producing the same are provided. The method includes a feeding step and a forming step. In the feeding step, a first resin, a second resin, and a third resin are respectively fed into a first extruder, a second extruder, and a third extruder to correspondingly form a composite transparent film having a first layer, a second layer, and a third layer. The first resin is selected from the group consisting of Tairilin 3824, Tairilin 3842, Tairilin 390A, Tairilin P115, Tairilin 663G, and SKYGREEN® S2008. In the forming step, the composite transparent film sequentially passes through a first forming wheel, a second forming wheel, and a third forming wheel to form a composite transparent board. The composite transparent board has a haze within a range from 0.75% to 4% and a total light transmittance within a range from 86% to 91.5%.