Melt-blown Polyamide Organo Sheet Production
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Solution Overview
Problem
The production of high-melting polyamide films using standard extrusion equipment often results in materials with voids, gel particles, streaks, and non-homogeneous surfaces, leading to inhomogeneous organo sheets with poor optical and mechanical performance, and is associated with low throughput and high conversion costs.
Innovation Solution
A process using melt-blow moulding technology to produce organo sheets with woven textiles and melt-blown polyamides, which offers a more economical alternative to extrusion, allowing for easier heating and melting, shorter cycle times, and improved intermingling with the textile, resulting in a more homogeneous product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard extrusion equipment is used to produce high-melting polyamide films, then the production process is established and equipment is available, but the resulting films exhibit voids, gel particles, streaks, and non-homogeneous surfaces leading to poor organo sheet quality
Solution Approach 1:
The patent changes the physical state parameters of the polyamide from solid film to melt-blown fibrous form. This parameter change allows the material to be applied to the textile at a different state, which then solidifies to form the matrix, avoiding the homogeneity issues of extrusion
Solution Approach 2:
The patent introduces an intermediary process (melt-blown conversion) between the polyamide production and the organo sheet formation. The polyamide is first converted to melt-blown fibrous material, which then serves as the matrix material for the organo sheet, eliminating direct extrusion onto the textile
2Productivity
If standard extrusion equipment is used to produce high-melting polyamide films, then the process is established, but the throughput is low and conversion costs are high
Solution Approach 1:
The patent performs preliminary action by converting the polyamide to melt-blown fibrous form before application to the textile. This preliminary conversion enables faster processing and higher throughput in the subsequent organo sheet production, as the melt-blown material can be more efficiently applied and consolidated
Solution Approach 2:
The patent changes the physical parameters of the polyamide from solid film to melt-blown fibrous material, which fundamentally alters the processing characteristics and enables higher productivity and lower conversion costs in the organo sheet production process
3Loss of time
If melt-blown polyamide is used instead of extruded film, then heating and melting is easier and cycle time is shorter, but the process requires melt-blow moulding technology
Solution Approach 1:
The patent utilizes phase transitions by applying heat to the melt-blown polyamide to transition it from a fibrous solid state to a molten state, enabling it to flow and intermingle with the textile fibres. This phase transition approach allows easier heating and shorter cycle times compared to extruded films
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 process produces organo sheets with improved mechanical and optical properties, achieving equivalent or better performance compared to extruded films, while allowing for easier handling and variation of basis weights, thus overcoming the limitations of traditional extrusion methods.
Implementation Method 1
While heating to temperatures above the melting point of the matrix polymer, the intrinsic rheology of the polymer is a major factor for sufficient penetration of the molten polymer in and between the fibres of the textile
Implementation Method 2
heating to temperatures above the melting point of the matrix polymer
Data Source
AI summary
The present invention relates to a process for the production of an organo sheet using a woven textile and a melt-blown polyamide and to the use of the obtained organo sheet in automotive, aviation, space travel, railway, drones, urban air mobility (UAM), and sports applications.