Graphite Film Sag Control via Multi-Core Heat Treatment
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Solution Overview
Problem
Existing methods for producing long and large-area graphite films fail to control sag, leading to uncontrolled distortion and limitations in lamination, rolling, and fitting to curved surfaces.
Innovation Solution
A graphite film with controlled sag forms, achieved by heat-treating the material graphite film to at least 2000°C while applying pressure, and using inner cores to create specific temperature gradients during the heat-treatment process, allowing for the formation of flat, middle, both-edge, and one-edge sag forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a polymeric film is heat-treated to produce a long and large-area graphite film, then the film area and length are improved, but sag control is lost and significant distortion occurs
Solution Approach 1:
The patent applies preliminary action by performing sag control heat treatment at a first temperature (500-1000°C) before the graphitization heat treatment at a second temperature (2000-3000°C). This preliminary heat treatment establishes the desired sag characteristics and flatness of the graphite film before the high-temperature graphitization process, ensuring that the final product maintains both large area and precise sag control without significant distortion
2Manufacturing precision
If heat treatment is applied to control sag, then flatness is improved, but production complexity increases due to multiple heat treatment steps
Solution Approach 1:
The patent merges two distinct heat treatment processes into a unified production method: (1) sag control heat treatment at 500-1000°C to establish flatness and control sag, and (2) graphitization heat treatment at 2000-3000°C to achieve the desired graphite structure. By combining these steps in sequence and using different temperature ranges for different purposes, the method achieves both flatness control and graphitization while managing process complexity through clear separation of functions
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 controlled sag forms enable improved lamination, reduced tearing, prevention of folded wrinkles, and enhanced fitting to curved surfaces, resulting in a graphite film with multiple beneficial properties in a single continuous sheet.
Implementation Method 1
heat-treating a polymeric film to not less than 2000°C while applying pressure to the material graphite film
Implementation Method 2
using inner cores to manage thermal expansion, allowing for multiple sag forms along the film's length
Data Source
AI summary
A re-forming process is carried out in which a material graphite film is heat-treated to not less than 2000° C. while the material graphite film is being pressured. Through the re-forming process, sag of a graphite film is controlled. By using, during the re-forming process, a plurality of inner cores having respective different surface states, it is possible to produce a graphite film having two or more sag forms which have respective effects.