Polymethylpentene Surface Layer for High-Temperature Film Production
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Solution Overview
Problem
Existing tapes used in the production of plastic films, such as those with a polypropylene surface layer, are limited by a maximum continuous use temperature of 160 °C, restricting production speeds and leading to increased emissions and complex manufacturing processes due to the need for additional heating of high-boiling solvents and auxiliary materials.
Innovation Solution
A tape with a flexible textile carrier layer and a temperature-resistant polymethylpentene surface layer, capable of operating between 170 °C and 200 °C, which allows for higher production speeds and direct heating of solvents during the manufacturing process, while maintaining precise three-dimensional structures and design options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polypropylene surface layer is used in the tape, then the tape can be manufactured with conventional materials and processes, but the continuous operating temperature is limited to no more than 160°C
Solution Approach 1:
The patent applies composite materials by combining a polypropylene base layer with a polymethylpentene surface layer. The polypropylene provides ease of manufacture and structural integrity, while the polymethylpentene surface layer enables continuous operating temperatures above 160°C (up to 200°C). This composite structure resolves the contradiction by allowing the tape to be manufactured with conventional materials (polypropylene) while achieving higher temperature resistance through the polymethylpentene coating.
2Productivity
If the continuous operating temperature is increased above 160°C, then production speeds can be significantly increased, but the polypropylene surface layer cannot withstand the temperature
Solution Approach 1:
The composite structure of polypropylene base layer with polymethylpentene surface layer enables the tape to withstand continuous operating temperatures of 170-200°C, which are necessary for high-speed production. The polymethylpentene layer has a melting point of 165-170°C and can operate continuously at temperatures up to 200°C, allowing production speeds to be increased without degrading the surface layer.
Solution Approach 2:
The patent changes the material parameter of the surface layer from polypropylene (melting point ~160°C) to polymethylpentene (melting point 165-170°C, continuous operating temperature up to 200°C). This parameter change allows the tape to operate at higher temperatures required for increased production speeds while maintaining surface integrity.
3Object-generated harmful factors
If additional processes are used to evaporate high-boiling solvents and additives, then the solvents can be removed from the product, but the manufacturing process becomes significantly complicated
Solution Approach 1:
The polymethylpentene surface layer enables the tape to withstand high temperatures (170-200°C) required for evaporating high-boiling solvents and additives directly during the manufacturing process. This eliminates the need for additional external evaporation equipment and processes, as the solvents can be removed in-situ during film production. The surface layer essentially serves the dual function of providing structural integrity and enabling solvent evaporation.
Solution Approach 2:
The patent merges the solvent evaporation function with the main manufacturing process by using the polymethylpentene surface layer to withstand the high temperatures needed for evaporation. Instead of having separate evaporation equipment and processes, the high-temperature resistance of the surface layer allows solvent removal to be integrated into the film production process itself, simplifying the overall manufacturing system.
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 higher production speeds, reduces emissions by eliminating the need for additional heating, and maintains precise embossed structures at elevated temperatures, expanding the application range to include polyurethane and PVC films and artificial leather production.
Implementation Method 1
the tape has a surface layer of polymethylpentene on at least one first side of the tape... enables a continuous operating temperature above 160°C, preferably in the range of 170°C ±5°C to 200°C ±10°C
Implementation Method 2
it is possible to evaporate high-boiling solvents and additives directly during the manufacturing process of the plastic film and thus remove them from the product being manufactured
Implementation Method 3
the polymethylpentene surface layer itself can reproduce very fine three-dimensional structures very precisely and permanently, whereby these three-dimensional structures are retained with very high accuracy even at the desired high continuous operating temperatures
Data Source
Figure 1
AI summary
The invention relates to a tape (10), in particular a grain tape, for the production of films, in particular plastic or elastomer films, such as rubber films, with a carrier layer (50) made of a textile fabric, in particular a woven fabric, wherein the tape (10) has on at least one first side of the tape a surface layer (20) made of polymethylpentene, preferably structured, as well as its production and use.