Optimization of Mesh Separator Systems for Interlayer Flow in Wound Gel Rolls

Mesh separators are typically used to maintain uniform fluid flow between gel roll layers during aging in the gel fabrication process. In order to reduce production cost and conserve energy, the manufacturing process must be optimized to reduce aging time. In this work we address the optimization of the mesh separators with respect to liquid flow rate. Several mesh separator designs were tested under aging conditions to determine the best separator configuration for maintaining uniform flow between gel layers to decrease aging time. Tests of single-layer separators resulted in very high pressure drops at low flow rates, indicating the flow channel was blocked by gel. A layered separator design performed best, producing significantly lower pressure drops for the same flow rates. Optimization of the separator system revealed two options as viable solutions: a foil layered system and a three layer net mesh system.