Polymeric Tape Lamination via Offset Stacking and Tension

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Solution Overview

Problem

Existing methods for producing multilayered articles from polymeric tapes require consolidating each layer, which can lead to distortions and inefficiencies, and do not allow for the production of laminates with the same properties without weaving or knitting processes.

Innovation Solution

A process involving the formation of monolayers of polymeric tapes under tension in a unidirectional, parallel manner, with each layer's direction being the same and offset to the adjacent layer, allowing for consolidation without individual layer fixation, using pressure and heat to bond the tapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If each monolayer of polymeric tapes is consolidated individually by applying pressure and heat, then the layer stability is improved, but the production complexity and time increase

Engineering Contradiction:

Improvelayer stabilityVSAvoidproduction efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent merges the consolidation step for multiple monolayers into a single simultaneous operation. Instead of consolidating each monolayer separately, the method allows stacking multiple monolayers and consolidating them together in one process step, thereby reducing production time and complexity while maintaining layer stability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies preliminary tensioning to the polymeric tapes before stacking and consolidation. This preliminary action of pre-tensioning the tapes ensures proper alignment and stability during the subsequent single consolidation step, eliminating the need for individual layer consolidation while maintaining structural integrity

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If polymeric tapes are formed into woven or knitted fabrics, then the structural stability is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent segments the manufacturing process into distinct stages: forming unidirectional monolayers with pre-tensioned tapes, stacking multiple monolayers, and then consolidating together. This segmentation avoids the complexity of weaving or knitting while maintaining structural stability through the stacking and consolidation approach

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of creating structural stability through complex weaving or knitting processes, the patent inverts the approach by using simple unidirectional monolayers that are stacked and consolidated. The structural stability is achieved through the consolidation of stacked layers rather than through interlacing tapes, thereby simplifying manufacturing

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If monolayers are crossplied at an angle to each other, then the impact resistance is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveimpact resistanceVSAvoidalignment precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent introduces asymmetry in the stacking arrangement by offsetting the position of tapes in adjacent monolayers. This asymmetric offsetting, combined with consolidation, creates interlocking structures that improve impact resistance while maintaining simple unidirectional alignment during manufacturing, avoiding the need for precise angular crossplying

Inventive Principle:

Principle #4Asymmetry

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

Enables the production of laminates with high tensile strength and impact resistance, achieving properties comparable to prior art methods without the need for consolidating each layer, and allows for the creation of lightweight, rigid panels with specific strength and weight characteristics.

Implementation Method 1

forming a first monolayer of polymeric tapes by pre-tensioning the polymeric tapes and subsequently positioning the polymeric tapes under tension in a unidirectional, parallel manner

Methodology Applied

Scientific EffectTension: Tension

Implementation Method 2

consolidating the thus stacked monolayers of polymeric tapes to obtain a laminate

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 3

consolidating the thus stacked monolayers of polymeric tapes to obtain a laminate

Methodology Applied

Scientific EffectPressure: Compression

Data Source

PatentUS9205636B2Process for producing laminates of unidirectionally arranged polymeric tapes

Publication Date: 2015.12.08 NOVAMEER

AI summary

Process for producing a laminate being built of at least two monolayers of polymeric tapes,the polymeric tapes having a tensile strength of at least 200 MPa, said process comprises the steps offorming a first monolayer of polymeric tapes by pre-tensioning the polymeric tapes and subsequently positioning the polymeric tapes under tension in a unidirectional, parallel manner,forming at least a second monolayer over the first monolayer in the same manner the first monolayer is formed, therebystacking the at least two monolayers of polymeric tapes in such a way that the direction of the polymeric tapes is the same in every monolayer and that the polymeric tapes of each monolayer are offset to the tapes of the adjoining monolayer above or below that monolayerconsolidating the thus stacked monolayers of polymeric tapes to obtain a laminate.