Interleaved Polymer Roll Winding for Uniform Gas Impregnation
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Solution Overview
Problem
Existing methods for making interleaved cylindrical rolls are inadequate for industrial-scale high pressure gas impregnation and solid-state foaming, particularly due to non-uniform gas distribution and compression issues in conventional rolling techniques.
Innovation Solution
A method and apparatus for interleaving a polymer film roll with a porous gas-permeable material roll using rotatable platforms that allow for zero or near zero tension winding, enabling vertical or adjustable orientations to create an interleaved cylindrical roll with even spacing, facilitating uniform gas impregnation across the roll's volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional horizontal rolling techniques are used to make interleaved cylindrical rolls, then the manufacturing process is simple, but gas distribution becomes non-uniform and compression issues occur
Solution Approach 1:
The patent transitions from horizontal rolling to vertical winding configuration, changing the spatial dimension of the interleaving process. The polymer film and porous material are wound vertically around a mandrel to form cylindrical rolls, allowing gravity to assist in achieving uniform spacing and preventing compression of the porous material during gas impregnation.
Solution Approach 2:
The invention employs adjustable winding tension control and variable winding speeds to dynamically optimize the interleaving process. The apparatus can adjust tension during winding to maintain zero or near-zero tension conditions, preventing compression while ensuring uniform layer spacing throughout the cylindrical roll formation.
2Manufacturing precision
If zero or near zero tension winding is used, then uniform gas impregnation is achieved, but the winding process requires precise tension control
Solution Approach 1:
The patent incorporates tension sensing feedback mechanisms that continuously monitor winding tension and automatically adjust winding parameters to maintain zero or near-zero tension conditions. This closed-loop control system simplifies operation by eliminating the need for manual tension adjustment while ensuring consistent layer spacing uniformity throughout the rolling process.
3Productivity
If larger diameter interleaved rolls are produced for industrial scale applications, then productivity increases, but non-uniform gas distribution and compression issues worsen
Solution Approach 1:
By transitioning to vertical cylindrical winding configuration, the patent enables production of large diameter rolls while maintaining uniform gas distribution. The vertical orientation allows gravity to act uniformly on all layers, preventing compression even in large diameter rolls, and the cylindrical geometry ensures consistent gas permeation pathways from the porous material to the polymer film throughout the entire roll volume.
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 solution allows for even and uniform gas impregnation throughout the interleaved roll, preventing compression of the gas-permeable material and ensuring consistent saturation, thereby improving the quality of microcellular foam production.
Implementation Method 1
a second porous gas permeable material sheet evenly wound about the central axis and interleaved with the first polymer film
Implementation Method 2
The foaming agent diffuses both outwards and into a large number of small cells
Implementation Method 3
a third rotatable platform for winding, while the first and second materials are unwinding, the first sheet material together with the second sheet material (under zero or near zero tension) to yield the interleaved cylindrical roll
Implementation Method 4
a polymer is saturated with a volatile foaming agent at a high pressure
Implementation Method 5
by means of a rapid pressure drop, the solubility of foaming agent impregnated within the polymer is decreased, and the polymer becomes supersaturated
Implementation Method 6
The system is heated to soften the polymer matrix and a large number of cells are nucleated
Implementation Method 7
by means of a rapid pressure drop, the solubility of foaming agent impregnated within the polymer is decreased
Implementation Method 8
bubble nucleation and growth is initiated by heating the polymer sheet
Implementation Method 9
The system is heated to soften the polymer matrix and a large number of cells are nucleated
Implementation Method 10
heating the polymer sheet to a temperature above the glass transition temperature of the polymer
Implementation Method 11
After foaming, bubble nucleation and growth is quenched by cooling the foamed polymer sheet
Data Source
AI summary
The present invention relates to apparatuses and methods for making interleaved cylindrical rolls from a polymer roll and a porous roll. The interleaved rolls disclosed herein are useful for subsequent high pressure gas impregnation and solid-state foam processing. In one embodiment, an interleaving apparatus comprises: a first rotatable platform for unwinding a first cylindrical roll of a first sheet material, the first rotatable platform being rotatable about a first central axis; a second rotatable platform for unwinding a second cylindrical roll of a second sheet material, the second rotatable platform being rotatable about a second central axis; and a third rotatable platform for winding, while the first and second materials are unwinding, the first sheet material together with the second sheet material to yield the interleaved cylindrical roll, the third rotatable platform being rotatable about a third axis and proximate to the first and second rotatable platforms.