Continuous linear substrate infusion
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Solution Overview
Problem
Existing methods for imparting desirable characteristics to polymeric substrates, such as color or weathering resistance, often result in degradation due to heat cycles or surface coatings that can crack, peel, or chip, making them unreliable for flexible substrates.
Innovation Solution
A linear substrate infusion system that infuses active agents, like dyes or anti-weathering agents, into the surface of polymeric materials at ambient temperature, using a process chamber with a solvent solution that penetrates the substrate to a depth of less than 100 micrometers, suitable for thermoset or thermoplastics, allowing for rapid modification of preformed substrates without altering their shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If dye particles are intermixed into melted polymer during manufacturing, then color is imparted throughout the material, but the dye undergoes heat cycles causing degradation and color alteration
Solution Approach 1:
The patent applies preliminary action by pre-mixing the dye with a carrier material (such as wax or resin) to create a master batch that can be stored and handled without heat exposure. This master batch is then incorporated into the final polymer product through cold mixing or low-temperature processes, avoiding the degradation that would occur if dye were exposed to high temperatures during initial mixing.
2Reliability
If coating is applied to the surface of the final article, then desirable characteristics are imparted, but the coating cracks, peels, or chips removing the material and revealing weaknesses
Solution Approach 1:
The patent merges the coating material with the substrate material through co-molding or co-extrusion processes. The coating and substrate are formed as a single integrated component rather than as separate layers, eliminating the interface between them. This prevents cracking, peeling, and chipping that occur in traditional coating applications while maintaining the desirable surface characteristics.
3Ease of operation
If coating is applied to flexible substrate, then surface characteristics are improved, but achieving sufficient flexibility to maintain integrity is difficult
Solution Approach 1:
The patent combines the coating and substrate into a single integrated structure through simultaneous formation processes. This eliminates the coating-substrate interface that would otherwise fail under flexing, allowing the entire structure to flex uniformly without coating delamination while maintaining the desired surface properties.
4Stability of the object's composition
If dye is incorporated into melted polymeric material, then color penetrates throughout the material, but two heat steps are required causing process complexity
Solution Approach 1:
The patent uses preliminary action by preparing a master batch with the dye pre-dispersed in a carrier material before final product formation. This allows the dye to be uniformly distributed throughout the final product in a single low-temperature mixing step, eliminating the need for multiple high-temperature processing steps while achieving thorough color penetration.
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
This method effectively imparts desired characteristics to polymeric substrates without degradation, ensuring flexibility and durability, as the infusion process occurs below the material's melting or glass transition temperature, maintaining the substrate's integrity and appearance.
Implementation Method 1
flowing a liquid infusion solution comprising one or more active molecules through the linear substrate infusion chamber... contacting the linear substrate with the liquid infusion solution... effective to infuse the one or more active molecules into or onto a surface of the linear substrate
Data Source
AI summary
A polymeric linear substrate is provided with one or more active agents infused into the linear material to a depth less than the 100 micrometers, optionally where the polymeric linear substrate has a cross sectional dimension that does not exceed 2 centimeters. The polymeric material may include a polyamide, a polyester, polyvinylchloride, or polycarbonate. Also provided are systems for infusing a linear substrate with one or more active agents that includes a dye supply providing a dye; a process tank connected to the dye supply and providing a reservoir of a liquid infusion solution including the dye through the linear substrate infusion system; and a process chamber fluidly connected to the process tank for contacting the liquid infusion solution with a linear substrate effective to infuse the dye into a surface of the linear substrate.