Ribbed Fluoroplastic Filter Support Sheet with Independent Aperture Pattern
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Solution Overview
Problem
Existing methods fail to produce high-purity, fluoroplastic filter members with a three-dimensional ribbed and apertured structure, where the aperture pattern is independent of the ribbed pattern, and previous techniques either produce poorly formed apertures or require pre-existing films, limiting flexibility and effectiveness in filtering applications.
Innovation Solution
A method involving extruding thermoplastic fluoroplastic material into a continuous sheet, forming ribs using counter-sunk grooves on rollers, and then punching apertures through the entire thickness in a predetermined pattern unaffected by the ribbed structure, allowing for flexible aperture placement and formation of continuous flow channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional embossing methods with projections are used to form pleats and apertures in fluoroplastic sheets, then the sheet structure is formed, but the aperture pattern is dictated by the rib pattern and aperture formation is poor
Solution Approach 1:
The patent separates the functions of rib formation and aperture formation into two independent steps: first forming ribs using embossing rolls with projections, then separately punching apertures using a punch press with a predetermined pattern. This segmentation allows the aperture pattern to be designed independently from the rib pattern, resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The patent performs preliminary rib formation before aperture punching. The ribs are formed first using embossing rolls, then the sheet is punched with apertures in a predetermined pattern. This preliminary action allows the rib structure to be established without compromising the subsequent aperture pattern precision.
2Adaptability or versatility
If fluoroplastic sheets are embossed and apertured using prior art methods, then some sheet structure is achieved, but the apertures are not clearly formed and flexibility in aperture patterning is limited
Solution Approach 1:
By separating rib formation and aperture punching into independent operations, the patent enables flexible aperture patterning without being constrained by the rib pattern. The punch press can create any aperture pattern desired, independent of how the ribs are configured, thus improving adaptability while maintaining precision.
Solution Approach 2:
The patent introduces an intermediary step where the fluoroplastic sheet is formed with ribs first, then serves as a substrate for subsequent aperture punching. This intermediary structure allows both the rib pattern and aperture pattern to be optimized independently, improving both versatility and precision.
3Reliability
If slits are cut into substrate to form apertures as in prior art, then aperture structure is created, but Z-direction force from filtrate flattens the substrate and closes apertures
Solution Approach 1:
The patent performs preliminary punching of apertures through the entire thickness of the ribbed sheet using a punch press. This creates fully formed, three-dimensional apertures that extend through the ribs and base section, providing structural support that prevents aperture closure under Z-direction filtration forces.
Solution Approach 2:
The patent creates localized reinforced structures around apertures through the punching process, where the ribbed structure provides structural support specifically at aperture locations. This local quality enhancement prevents aperture collapse under filtration pressure while maintaining the overall substrate integrity.
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 approach enables the creation of filter members with precise aperture patterns and ribbed structures that enhance fluid filtration efficiency by directing fluids through channels and apertures, improving the filtering process without the limitations of previous methods.
Implementation Method 1
extruding a thermoplastic fluoroplastic material through an extrusion die in the form of a continuous sheet
Implementation Method 2
passing said sheets through a nip region provided by opposed rollers having outer surfaces, said outer surfaces being free of projections extending outwardly therefrom, at least one of said outer surface including counter-sunk grooves therein
Implementation Method 3
punching apertures through the entire thickness of said ribbed sheet in a predetermined pattern unaffected by the three-dimensional pattern of ribs
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A filter support sheet extruded from a fluoroplastic material includes a base section having spaced-apart ribs extending outwardly from at least one surface thereof. Segments between spaced-apart ribs provide flow channels and apertures are punched through the sheet in a predetermined pattern unaffected by the structure of the support sheet. A method includes the steps of: (1) extruding a thermoplastic, fluoroplastic material to form of a sheet; (2) passing the sheet through a nip region provided by opposed rollers; at least one having an outer surface with counter-sunk grooves. Counter-sunk grooves in one roller are aligned with an outer surface or counter-sunk grooves of the other roller in the nip region to form a ribbed sheet having ribs upstanding from at least one surface of said sheet; (3) setting the ribbed sheet and (4) punching apertures through the ribbed sheet in a predetermined pattern.