Microporous Polyolefin Sheet Rectifier Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Increasing film formation speed leads to increased air trapping pressure and discharge of low-molecular-weight components, diluents, and additives, causing contamination of the cooling/hardening device due to incomplete aspiration of gases and liquids in the decompression chamber.
Innovation Solution
A production device with a decompression chamber and a rectifier that maintains a lower pressure inside the rectifier than the decompression chamber, featuring openings on the rectifier to aspirate and remove liquids and gases, preventing contamination by actively removing low-molecular-weight components and additives before they accumulate and drop onto the cooling/hardening device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If film formation speed is increased, then productivity is improved, but air trapping pressure increases and causes adhesion problems and sheet defects
Solution Approach 1:
The decompression chamber is divided into multiple chambers with different pressure levels. The first decompression chamber operates at a higher pressure (-10 to -100 mmHg) to prevent adhesion problems at high speed, while the second decompression chamber operates at a lower pressure (-100 to -500 mmHg) to remove volatile components effectively. This segmentation allows simultaneous achievement of stable adhesion and contaminant removal.
Solution Approach 2:
A pressure gradient is introduced as an intermediary mechanism between the two decompression chambers. The gradual pressure transition from the first to the second chamber allows controlled aspiration of air and volatile components without causing sudden pressure changes that would disrupt adhesion, thus mediating between the conflicting requirements of high-speed production and defect prevention.
2Reliability
If decompression chamber aspiration is increased to remove air, then adhesion is improved, but more low-molecular-weight components are aspirated and liquefied, causing contamination
Solution Approach 1:
The decompression process is segmented into two stages with different pressure levels. The first chamber at higher pressure removes air for adhesion without aspirating excessive volatile components. The second chamber at lower pressure handles the removal of volatile components that have already evaporated from the sheet surface, preventing their liquefaction and contamination.
Solution Approach 2:
The first decompression chamber performs preliminary air removal to establish stable adhesion before the sheet enters the second chamber. This preliminary action prevents air trapping issues while limiting the aspiration of volatile components to manageable levels, preparing the sheet for the second stage of volatile component removal.
3Device complexity
If single-pressure decompression is used, then device complexity is reduced, but cannot simultaneously achieve stable adhesion and prevent liquid droplet formation
Solution Approach 1:
The decompression system is segmented into two chambers with distinct pressure zones. This segmentation enables independent optimization of each chamber's pressure level to address different aspects of sheet quality: the first chamber optimizes for adhesion stability while the second optimizes for contaminant removal, achieving high manufacturing precision without excessive complexity.
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 solution effectively suppresses the dropping of liquids onto the cooling/hardening device, ensuring stable high-speed film formation by forcibly aspirating and removing low-molecular-weight components and additives, thereby preventing sheet defects and maintaining device cleanliness.
Implementation Method 1
a first decompression chamber 10 and a rectifier 11 that aspirates inside the rectifier 11, wherein a pressure inside the rectifier 11 is lower than a pressure inside the decompression chamber 10
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An object is to prevent the occurrence of sheet defects by preventing the dropping of a liquid of low-molecular-weight components in a polymer, diluents, and additives adhering to a rectifier disposed inside a decompression chamber in a production method for a microporous polyolefin resin sheet including discharging a solution including a mixture of a polyolefin resin and a diluent in a sheet shape from a mouthpiece to a cooling/hardening device and cooling the sheet while aspirating the air between the sheet and the cooling/hardening device with an aspiration chamber. Another object is to forcibly aspirate a liquid of low-molecular-weight components in a polymer, diluents, and additives adhering to the rectifier by, while using a production device for a microporous polyolefin resin sheet having a mouthpiece that discharges a liquid including a mixture of a polyolefin resin and a diluent in a sheet shape, a cooling/hardening device that cools the sheet discharged from the mouthpiece, and a decompression chamber that aspirates the air between the sheet and the cooling/hardening device, disposing a rectifier inside the decompression chamber, aspirating each of the inside of the decompression chamber and the inside of the rectifier, and keeping the pressure inside the rectifier lower than the pressure inside the decompression chamber.