Reverse Roll Construction for Laminated Material Delamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional roll constructions of laminated materials suffer from premature delamination of the polymer layer from the backer film during unwinding, leading to inadequate performance in applications like fuel cells and flow batteries.
Innovation Solution
A reverse roll construction is developed where the polymer layer, release film, and base layer are oriented such that the polymer layer is on the outer surface of the backer film, with the base layer contacting the core and the release film bonded to the polymer layer, inhibiting delamination by adjusting the layer directionality during the rolling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the traditional roll construction is used with the polymer layer on the inner surface of the backer film, then the laminated material can be easily formed and rolled, but the polymer layer delaminates from the backer film during unwinding
Solution Approach 1:
The patent inverts the traditional layer arrangement by placing the polymer layer on the outer surface of the backer film instead of the inner surface. This reversal changes the unwinding mechanism: during unwinding, the polymer layer of a subsequent layer contacts the release film of the previous layer, allowing clean separation without delamination. The inversion resolves the contradiction by maintaining manufacturing simplicity while eliminating the delamination problem through reversed layer orientation.
Solution Approach 2:
The release film is positioned between the polymer layer and the base layer in advance, creating a predetermined separation interface. During rolling and unwinding, this pre-positioned release film ensures that the polymer layer separates cleanly from the base layer at the intended location, preventing premature delamination while maintaining ease of manufacture.
2Device complexity
If the polymer layer is positioned on the inner surface of the backer film in traditional roll construction, then the rolling process is simplified, but the polymer layer remains attached to the previously rolled layer during unwinding
Solution Approach 1:
By inverting the layer arrangement to place the polymer layer on the outer surface, the patent simplifies the unwinding operation. During unwinding, the polymer layer naturally separates from the previous layer at the release film interface, eliminating the need for complex separation mechanisms and improving ease of operation while keeping the rolling process simple.
3Productivity
If the traditional layer directionality is used during rolling, then the manufacturing process is straightforward, but the laminated material loses integrity during unwinding
Solution Approach 1:
The patent inverts the layer directionality during rolling, placing the polymer layer on the outer surface of the backer film. This inversion maintains manufacturing efficiency by using a straightforward rolling process while ensuring laminated material integrity during unwinding, as the polymer layer separates cleanly at the pre-positioned release film interface rather than delaminating prematurely.
Solution Approach 2:
The release film acts as an intermediary layer between the polymer layer and the base layer. This intermediary ensures that during unwinding, the polymer layer separates cleanly from the previous layer without compromising the integrity of the laminated material structure, maintaining both manufacturing efficiency and material stability.
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 orientation significantly reduces the likelihood of delamination during unwinding, ensuring the polymer layer remains intact and functional, thereby maintaining the integrity and performance of the laminated material in applications.
Implementation Method 1
the outer surface of the release film being bonded to the inner surface of the ion-exchange resin layer
Implementation Method 2
the outer surface of the base layer being bonded to the inner surface of the release film
Data Source
AI summary
The present invention relates to a roll construction of laminated material that inhibits delamination of the polymer layer from a backer film upon unwinding of the roll construction. Particularly, aspects of the present invention are directed to a roll construction of laminated material prepared by a process that includes providing the laminated material having an ion-exchange resin layer, a release film, and a base layer, and feeding the laminated material to a roller to generate the roll of the laminated material. The laminated material is fed to the roller such that a first layer of the laminated material wound around the core includes the inner surface of the base layer of the first layer contacting an outer surface of the core.