Extrusion Perforation Roll Nip for Single-Step Thermoplastic Film
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Solution Overview
Problem
The manufacturing of perforated extruded thermoplastic films and sheets typically requires multiple steps, including extrusion into master rolls followed by secondary processing for perforation, which is inefficient and generates waste.
Innovation Solution
A single-step extrusion system that integrates a thermoplastic extrusion die, a perforation/embossed roll, and a resilient/pressure backing nip roll, allowing for in-situ perforation of thermoplastic materials during the extrusion process without the need for secondary operations, using controlled mechanical and thermal stresses to create perforations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multi-step process is used to manufacture perforated extruded thermoplastic films, then the perforation quality can be maintained through secondary processing, but the manufacturing complexity and time increase
Solution Approach 1:
The patent combines the extrusion process and perforation process into a single integrated operation. The extrusion die directly forms the perforated structure in the thermoplastic material as it exits the die, eliminating the need for separate perforation equipment and secondary processing steps. This merging of operations reduces manufacturing complexity while maintaining perforation quality through precise die design.
2Manufacturing precision
If a multi-step process with master rolls is used, then the extrusion quality can be controlled, but the production time and handling requirements increase
Solution Approach 1:
The patent performs the perforation action during the extrusion process itself, before the material is fully formed and cooled. The extrusion die is designed with features that create the perforated structure in the molten thermoplastic as it exits, allowing both extrusion quality control and perforation to be achieved in one continuous operation without requiring intermediate handling or storage of master rolls.
3Manufacturing precision
If secondary processing operations are used for perforation, then the perforation precision can be achieved, but material waste and handling complexity increase
Solution Approach 1:
The patent merges the perforation function into the extrusion die design, allowing perforations to be created directly during the extrusion process. This eliminates material waste associated with secondary perforation operations such as punching or drilling, where material is removed or subjected to additional stress. The perforated structure is formed positively during extrusion without requiring subsequent material removal or handling.
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 system reduces waste and simplifies the manufacturing process by integrating perforation into the extrusion step, enhancing product quality and reducing costs by eliminating the need for secondary processing and handling.
Implementation Method 1
a system to pump a thermoplastic resin melt through an extrusion die
Implementation Method 2
the extruded thermoplastic resin melt travels between the perforation/embossed roll and the resilient/pressure backing nip roll... and subsequently released from the resilient/pressure backing nip roll as a perforated film
Data Source
AI summary
An extrusion system includes a system to pump a thermoplastic resin melt through an extrusion die, the thermoplastic resin including a polymer base whose rheological properties are modified using fillers, a perforation/embossed roll, and a resilient/pressure backing nip roll through which the extruded thermoplastic resin melt travels between the perforation/embossed roll and the resilient/pressure backing nip roll in a roll nip/station area, exiting the roll nip/station area and around the resilient/pressure backing nip roll and subsequently released from the resilient/pressure backing nip roll as a perforated film, film or fabric carrier supported perforated film, coex laminate, or cut into sheet