Oriented Polymer Composition Deoriented Surface Layer

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Solution Overview

Problem

Oriented polymer compositions (OPCs) face challenges with fibrillation, limited structural integrity, and density issues, particularly when cut transverse to their orientation direction, and existing methods like ram extrusion are batch processes that do not allow for cavitation.

Innovation Solution

A continuous process that de-orientates a surface layer of OPCs while maintaining orientation in other areas, achieving a cavitated OPC with a de-oriented surface layer and an oriented core, allowing for improved cutability and structural integrity through controlled heating and tensile drawing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If an oriented polymer composition is created to increase flexural modulus, then strength is improved, but fibrillation occurs along the orientation direction

Engineering Contradiction:

Improveflexural modulusVSAvoidfibrillation resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies local quality by creating a composite structure where the core region has high polymer orientation for flexural modulus while the skin region has low orientation to prevent fibrillation. This spatial differentiation of orientation levels allows each region to perform its specific function optimally.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the polymer composition into distinct core and skin regions with different orientation characteristics. The core contains highly oriented polymer chains for strength, while the skin contains randomly oriented chains for surface integrity, effectively dividing the structure into functional zones.

Inventive Principle:

Principle #1Segmentation

2Reliability

If ram extrusion method is used to create low orientation skin and high orientation core, then structural integrity is improved, but cavitation cannot be achieved

Engineering Contradiction:

Improvestructural integrityVSAvoiddensity

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent inverts the conventional approach by using tensile drawing instead of compressive ram extrusion. This inversion enables cavitation to occur during the orientation process, allowing density reduction while still achieving the desired core-skin orientation structure.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent implements a continuous tensile drawing process that simultaneously achieves orientation, cavitation, and core-skin structure formation in one continuous operation, eliminating the need for separate batch processing steps.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If tensile drawing process is used to achieve cavitation and reduce density, then productivity is improved, but surface fibrillation problems persist

Engineering Contradiction:

Improvecontinuous processingVSAvoidsurface integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies local quality by creating different orientation levels in different regions: the skin is deliberately kept with low orientation to prevent fibrillation, while the core achieves high orientation for strength, all within a continuous tensile drawing process.

Inventive Principle:

Principle #3Local quality

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 results in OPCs with high flexural modulus, reduced density, and enhanced cutability transverse to the orientation axis, with a de-oriented surface layer thickness of 80 microns significantly improving cutability and maintaining low variability.

Implementation Method 1

Cavitation is desirable to reduce OPC density to facilitate shipping and handling of the OPC as well as overall structure weight for structures containing the OPC

Methodology Applied

Scientific EffectCavitation: Cavitation

Implementation Method 2

heating at least one surface of the oriented polymer composition above its softening temperature thereby de-orienting the polymers proximate to the surface

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

Orienting a polymer composition strengthens the polymer composition by aligning polymer chains in a particular direction

Methodology Applied

Scientific EffectTensile drawing: Tension

Data Source

PatentUS8475700B2Oriented polymer composition with a deoriented surface layer

Publication Date: 2013.07.02 EOVATIONS LLC

AI summary

Prepare an oriented polymer composition that is cavitated, has cross sectional dimensions all at least three millimeters and at least one de-oriented surface layer having a thickness of at least 80 microns and at least 50 microns less than half the thickness of the oriented polymer composition, the de-oriented surface layer having a lower degree of polymer orientation than a 100 micron thick portion of the oriented polymer composition adjacent to and below the de-oriented surface layer by sufficiently heat treating a surface of a cavitated oriented polymer composition.