Polymer Coating Process for Uniform Bristle Layers
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Solution Overview
Problem
Existing methods for producing polymer-containing layers on carrier materials are limited in producing uniform, adjustable coatings with high additive content, leading to disturbed textile properties and machine component abrasion, and are not suitable for sensitive additives or large abrasive particles.
Innovation Solution
A process involving direct dissolution of polymers in solvents, forced wetting, and viscoelastic relaxation to form a solid polymer layer on a carrier material, allowing for uniform layer thickness and high additive incorporation without disturbing the carrier material's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating processes are used to produce polymer layers on carrier materials, then the coating can be applied, but the layer thickness cannot be uniformly controlled and adjusted, and high additive content disturbs the textile properties
Solution Approach 1:
The patent applies parameter changes by controlling the coagulation bath temperature, composition, and flow rate to precisely regulate polymer layer thickness and uniformity. By adjusting these parameters, the process achieves consistent coating thickness while accommodating high additive content without disturbing carrier material properties
Solution Approach 2:
The patent utilizes phase transition of the polymer solution during coagulation, where the polymer precipitates from solution to form a solid layer on the carrier. This controlled phase transition enables uniform layer formation with adjustable thickness and high additive incorporation while maintaining carrier material integrity
2Quantity of substance
If high proportions of additives are incorporated into the coating, then the functional properties are enhanced, but the textile-physical properties of fibers and filaments decrease
Solution Approach 1:
The controlled coagulation process allows high additive content to be incorporated uniformly during the phase transition from solution to solid polymer layer, preventing additive aggregation that would otherwise weaken the fiber structure
Solution Approach 2:
The patent creates a composite structure where additives are uniformly distributed within the polymer matrix during coagulation, forming a homogeneous composite material that maintains structural integrity and textile properties even with high additive proportions
3Productivity
If abrasive particles are used in the coating, then the functional properties for grinding and cleaning are improved, but machine components experience abrasion
Solution Approach 1:
The coagulation process encapsulates abrasive particles within the forming polymer layer, securing them in place and preventing them from escaping and damaging machine components during processing
Solution Approach 2:
The patent creates a composite coating where abrasive particles are uniformly distributed and embedded in the polymer matrix, providing grinding and cleaning functionality while the polymer binding prevents particle detachment and machine wear
4Quantity of substance
If sensitive additives are incorporated into the coating, then the functional properties are enhanced, but the additives are damaged by shear forces during conventional processing
Solution Approach 1:
The coagulation process occurs through controlled phase transition rather than high-shear mixing, allowing sensitive additives to be incorporated intact during the precipitation process without mechanical damage to their structure or function
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 enables the production of strong, uniform polymer coatings with high additive content, maintaining the carrier material's properties and preventing abrasion, suitable for sensitive additives and large abrasive particles, with a high-strength connection between the carrier and coating.
Implementation Method 1
the polymers align in the preliminary layer and relax viscoelastically
Implementation Method 2
removing the solvent from the polymer solution layer
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
The invention relates to a moulded body having a polymeric coating and a method for the production thereof. In the method: a) a cladding material is prepared from a polymer solution by dissolving polymers in a solvent by a direct dissolving process, b) a carrier material is guided at a defined speed through a feed channel and through an outlet opening into a coating chamber, wherein the feed channel traverses a container holding the cladding material, c) the cladding material is guided through a predefined gap and at a defined pressure into the coating chamber, where contact is effected between the cladding material and the carrier material and a preliminary layer of cladding material forms on the carrier material as a result of forced wetting in a variable pressure equilibrium and flow equilibrium within the coating chamber, d) the carrier material having the layer are together guided through a further outlet opening, e) the cladding material in the container, in the coating chamber and upstream of the outlet opening is temperature-controlled, f) the carrier material coated with the cladding material passes through a relaxation zone in order to orient the polymers and for visco-elastic relaxation in order to achieve the final low-stress polymer solution layer, g) by setting the withdrawal of the carrier material from the coating chamber via the outlet opening into the relaxation zone, the cladding material, the carrier material or both can be additionally distorted, h) and the solvent can be removed from the polymer solution layer. The moulded bodies are preferably fibres, in particular bristles, from which brushes or paint brushes can be made.