Crosslinked Polyolefin Foam Embossing Integrated Into Extrusion
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Solution Overview
Problem
Existing methods for producing crosslinked polyolefin foam sheets require a separate embossing step after foaming, which increases manufacturing complexity and costs.
Innovation Solution
Integrate the embossing step into the extrusion process of the foam production, allowing for the embossing of the unfoamed or foamable sheet before irradiation and foaming, thereby eliminating the need for a post-embossing operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional post-embossing operation is used after foaming, then the foam sheet surface can be embossed, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent combines the embossing operation with the extrusion process by integrating an embossing roll into the extrusion line. This merging of operations allows the foamable composition to be embossed during extrusion before foaming, eliminating the need for a separate post-embossing operation and thereby reducing manufacturing complexity while achieving the desired embossed surface.
Solution Approach 2:
The patent applies embossing to the foamable composition during the extrusion process before the foaming step. This preliminary embossing action ensures that the embossed pattern is established on the sheet before foaming occurs, allowing the pattern to be preserved through the subsequent foaming process without requiring post-embossing operations.
2Shape
If separate embossing equipment is used after foaming, then the foam sheet can be embossed, but the production time and manufacturing costs increase
Solution Approach 1:
The patent merges the embossing operation into the extrusion process, combining two previously separate operations (extrusion and embossing) into a single integrated step. This eliminates the need for separate embossing equipment and post-embossing operations, thereby reducing production time and improving manufacturing efficiency while still achieving the required embossed surface.
Solution Approach 2:
The patent performs embossing as a preliminary action during extrusion before foaming. This timing allows the embossed pattern to be established on the foamable composition while it is still in a workable state, and the pattern is preserved through the subsequent foaming process, eliminating the need for post-embossing and improving overall production efficiency.
3Reliability
If multiple manufacturing steps are used for foam production, then the foam sheet can be produced with required properties, but the manufacturing costs increase
Solution Approach 1:
The patent combines multiple manufacturing steps (extrusion and embossing) into a single integrated operation by incorporating an embossing roll into the extrusion line. This merging reduces the total number of manufacturing steps, thereby reducing manufacturing costs while still producing foam sheets with the required properties through the integrated process.
Solution Approach 2:
The patent performs embossing as a preliminary action during extrusion before foaming. This timing allows the embossed pattern to be established on the foamable composition while it is still in a workable state, and the pattern is preserved through the subsequent foaming process, eliminating the need for post-embossing operations and reducing overall manufacturing costs.
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
This approach simplifies the production process, reduces manufacturing steps, and lowers costs by integrating embossing directly into the extrusion process, resulting in a more efficient manufacturing method for crosslinked polyolefin foam sheets.
Implementation Method 1
irradiating the embedded foamable sheet with ionizing radiation; the ionizing radiation crosslinks the embedded foamable sheet to a crosslinking degree of 20-75%
Implementation Method 2
foaming the irradiated foamable sheet; foaming comprises heating the irradiated foamable sheet with molten salt and radiant heaters or a hot air oven
Data Source
AI summary
Described herein are physically crosslinked polyolefin, embossed closed cell continuous foam structures. The embossing can be performed during the extrusion step such that at least one surface of an extruded foamable sheet can be embossed with a pattern before the irradiation and foaming of the foamable sheet.