DESC:CROSS REFERENCE TO RELATED APPLICATION
This Application is based on and derives the benefit of Indian Provisional Application 202141013179 filed on 25/03/2021, the contents of which are incorporated herein by reference.

TECHNICAL FIELD
[001] The embodiments herein relate to a method for making washer sheets and a washer sheet composition thereof.

BACKGROUND
[002] Flanged bolted assemblies are widely used in many industrial applications for sealing. Sealing is intended to avoid leakage, corrosion, abrasion, noise and torque retention of these flanged bolted joints. Presently, the washers are made of copper, aluminum, brass, rubber, rubber with metal casing, gaskets and paste washers. But the above solutions have drawbacks like high cost, high weight, rigidity, material abrasion and are not operator friendly. For example, Aluminum, Copper and Brass are precious earth metals and require series of manufacturing operations involving energy and waste generation. Rubber/ rubber with metal are difficult to manufacture and implement. Here the positioning (orientation) of the washer is difficult and is one of the challenges posed to the original equipment manufacturers (OEM’s). Further, gaskets are high costs. And adhesive pastes are not reliable because of variability in applied volume and cost.
[003] Therefore, there exists a need for a method for making washer sheets and a washer sheet composition, which obviates the aforementioned drawbacks.

OBJECTS
[004] The principal object of an embodiment herein is to provide a method for making washer sheets.
[005] Another object of an embodiment herein is to provide a washer sheet composition.
[006] Another object of an embodiment herein is to provide a washer which is lightweight and durable.
[007] Another object of an embodiment herein is to provide the washer which is recyclable and consumes very less sealing agent.
[008] Another object of an embodiment herein is to provide the washer which is self-orienting in sealing applications.
[009] Another object of an embodiment herein is to provide the washer which involves no tedious manufacturing operations.
[0010] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0011] The embodiments of the invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0012] Fig. 1 illustrates an electrode used in an electro-spinning process for making washer sheet;
[0013] Fig. 2 depicts a flowchart showing steps of a method for making washer sheet, according to embodiments as disclosed herein;
[0014] Fig. 3 depicts washers, according to embodiments as disclosed herein; and
[0015] Fig. 4 depicts washer fitted on a flanged bolt, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0016] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0017] The embodiments herein achieve a method for making washer sheets and a washer sheet composition thereof. Referring now to the drawings, and more particularly to Fig. 1 through Fig. 4, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0018] Fig. 1 illustrates an electrode (10) used in an electro-spinning process for making washer sheet. Electro-spinning is a fiber production method that uses an electric force to draw charged threads of polymer solutions or polymer melts up to fiber diameters in the order of some hundred nanometers. The process does not require the use of coagulation chemistry or high temperature to produce solid threads from solution which can be converted to sheets of desired thickness or GSM.
[0019] Fig. 2 depicts a flowchart showing steps of a method (100) for making washer sheet, according to embodiments as disclosed herein. For the purpose of this description and ease of understanding, the method (100) herein is explained with reference to making washer sheets. However, it is also within the scope of this invention to practice/implement the entire steps of the method (100) in a same manner or in a different manner or with omission of at least one step to the method (100) or with any addition of at least one step to the method (100) for making washer sheet. At step (102), the method (100) includes, selecting a polymer and an aqueous sealant. At step (104), the method includes, preparing polymer and aqueous sealant solution in a proportioned ratio. At step (106), the method (100) includes, forming the washer sheet through an electro-spinning process. For the purpose of this description and ease of understanding, the polymer is considered to be nylon 6,6 grade, and the aqueous sealant is a polyacrylate based aqueous sealant. It is also within the scope of the invention to provide nylon 4, nylon 4, 6, nylon 12, polyesters or any other polymers materials in place of nylon 6, 6 material. Further, it is also within the scope of the invention to provide any other sealant material in place of polyacrylate based aqueous sealant. The proportioned ratio at which the aqueous sealant is infused with the polymer to prepare the polymer and aqueous solution is 50:50.
[0020] The method step (106) of forming the washer sheet through an electro-spinning process includes, providing the polymer and aqueous sealant solution to at least one electrode (10); applying, by a voltage source, a high voltage power supply to the polymer and aqueous sealant solution; and forming washer sheet by allowing the polymer and aqueous sealant solution flow from the electrode (10) in form of Taylor cone when charge (voltage) reaches a threshold point. For the purpose of this description and ease of understanding, the electrode (10) can also be called as syringe, nozzles, capillaries and so on, according to the electro-spinning technology being employed.
[0021] The method (100) includes, setting the voltage in a range of 20 to 25 kV (kilo volt); maintaining a rotation of a roller drum in range of 500 to 2000 rpm (revolutions per minute); maintaining a distance of 12 to 15 cm (centimeter) between a tip of the electrode (10) and the roller drum; and setting a feed rate in range of ~ 0.5 to 1 mLh (milliliters per hour). For the purpose of this description and ease of understanding, the tip of the electrode (10) can also be called as orifice of the electrode (10). Further, drum is also called as collector.
[0022] Further, the method (100) includes, cutting the washer sheet to facilitate formation of a washer (as shown in fig. 3a and fig. 3b) in predefined shape by using laser cut process.
[0023] Further, embodiments herein disclose about a washer sheet composition. The washer sheet composition comprises, a polymer and a polyacrylate based aqueous sealant, wherein polymer is present in an amount of 50 wt% of the total composition, and polyacrylate based aqueous sealant is present in an amount of 50 wt% of the total composition.
[0024] Fig. 3 depicts washers, according to embodiments as disclosed herein. Fig. 4 depicts washer fitted on a flanged bolt, according to embodiments as disclosed herein. The washer can be fitted on flange bolts, drain plugs etc. In this method we have used an electro-spun nylon as a carrier that was impregnated with a polyacrylate aqueous emulsion based pre-applied sealant. Sealant impregnated film will have the flexibility in terms of design, dimensions and temperature and can be prepared as per the application requirements. The sealant is impregnated on carrier film by using screen printing method. This washer can be used for assembly of parts with tightening torque of 40-45 Nm. Polyacrylate aqueous emulsion impregnated film will be able to seal by filling the micro gaps and provides mechanical locking in variety of substrates like metal, plastics etc.
[0025] The technical advantages of the washer are as follows. The washer is lightweight (1 copper washer > 40 Nos. of the polymer-aqueous sealant based washer by weight). The washer is made from recyclable nylon material and water-based sealant and involves no tedious manufacturing operation. Consumes lesser energy for making the washer. Consumes very less sealing agent. Self-orienting as it can be made with precision tolerance. Solvent free.
[0026] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim:
1. A method (100) of making a washer sheet, said method (100) comprising:
selecting a polymer and an aqueous sealant;
preparing polymer and aqueous sealant solution in a proportioned ratio; and
forming the washer sheet through an electro-spinning process.

2. The method (100) as claimed in claim 1, wherein the polymer is nylon 6,6 grade;
the aqueous sealant is a polyacrylate based aqueous sealant; and
the proportioned ratio at which the aqueous sealant is infused with the polymer to prepare the polymer and aqueous solution is 50:50.

3. The method (100) as claimed in claim 1, wherein said forming the washer sheet through the electro-spinning process includes,
providing the polymer and aqueous sealant solution to at least one electrode (10);
applying, by a voltage source, a voltage to the polymer and aqueous sealant solution; and
forming washer sheet by allowing the polymer and aqueous sealant solution flow from the electrode (10) in form of Taylor cone when charge (voltage) reaches a threshold point.

4. The method (100) as claimed in claim 3, wherein said method (100) includes,
setting the voltage in a range of 20 to 25 kV;
maintaining a rotation of a roller drum in range of 500 to 2000 rpm;
maintaining a distance of 12 to 15 cm between a tip of the electrode (10) and the roller drum; and
setting a feed rate in range of ~ 0.5 to 1 mL/h.
5. The method (100) as claimed in claim 1, wherein said method (100) includes,
cutting the washer sheet to facilitate formation of a washer in predefined shape by using laser cut process.

6. A washer sheet composition comprising:
a polymer; and
a polyacrylate based aqueous sealant.

7. The washer sheet composition as claimed in claim 1, wherein said polymer is present in an amount of 50 wt% of the total composition; and
said polyacrylate based aqueous sealant is present in an amount of 50 wt% of the total composition.

8. The washer sheet composition as clamed in claim 6, wherein the polymer is at least nylon 6,6 grade.