System and method for preparing carbon rods

Abstract

The present application relates to water purification equipment technical field, specifically provide a kind of preparation system and preparation method of carbon rod, to solve the problem of huge invalid heat load in the preparation process of existing activated carbon filter element, low energy utilization efficiency.For this purpose, the preparation system of carbon rod of the present application includes mold, mold includes: cavity, formed in the mold inside, for accommodating the raw material required for preparing carbon rod;First heating part, close to the outside or inside of mold cavity, or embedded in the side wall of mold cavity, for independently heating the raw material in each mold cavity.By closely combining the first heating part with the mold, while achieving independent heating of each mold, it can also more efficiently transfer heat to the raw material in the mold, thereby improving the heating efficiency of the raw material and reducing energy consumption.

Description

Technical Field

[0001] This invention relates to the field of water purification equipment technology, specifically providing a carbon rod preparation system and preparation method. Background Technology

[0002] Activated carbon filter cartridges are key components in water purification. Their core manufacturing process involves shaping activated carbon powder, binders, and other raw materials into a predetermined shape and then solidifying them. Currently, the mainstream industrial manufacturing technologies mainly fall into two categories: extrusion and sintering. However, both have inherent limitations in terms of energy consumption and molding control.

[0003] The typical process of "extrusion molding" involves continuously heating, mixing, and plasticizing pre-mixed charcoal powder and molten binder in the feed tube of a high-temperature extruder (such as a screw extruder), typically at 220°C or higher, to create a homogeneous plastic body. This body is then extruded through a die and finally cut into charcoal rods of a predetermined length. While this method allows for continuous production, the entire feed pipeline and materials must maintain a high temperature for an extended period, resulting in significant energy loss. Furthermore, the materials are under continuous shearing and conveying during the heating process, leading to high energy consumption. Simultaneously, precise control of the final product's basis weight and density relies on the precise coordination of multiple dynamic parameters, such as extrusion speed and cutting accuracy, making control quite challenging.

[0004] The typical process of "sintering" molding is as follows: dry mixed raw materials are filled into molding molds, and then multiple molds containing the materials are placed in a large high-temperature furnace. Static heating and sintering are carried out at a set temperature for an extended period, causing the binder to melt and solidify. Finally, the molds are cooled and demolded. A significant drawback of this process is that it requires prolonged heating and insulation of the entire large furnace space (containing numerous molds and air), resulting in a huge ineffective heat load, low energy efficiency, and a long production cycle.

[0005] In view of this, a new technical solution is needed in this field to solve the above problems. Summary of the Invention

[0006] The present invention aims to solve the above-mentioned technical problems, namely, to solve the problems of huge ineffective heat load and low energy utilization efficiency in the existing activated carbon filter element preparation process.

[0007] In a first aspect, the present invention provides a carbon rod preparation system, including a mold, the mold comprising: a cavity formed inside the mold for accommodating raw materials required for preparing carbon rods; and a first heating element fitted and covering the outside or inside of the mold cavity, or embedded in the side wall of the mold cavity, for independently heating the raw materials in each mold cavity.

[0008] In a preferred embodiment of the carbon rod preparation system described above, the preparation system further includes a second heating element for preheating the raw material before it is injected into the mold cavity.

[0009] In a preferred embodiment of the carbon rod preparation system described above, the preparation system further includes a feed tube assembly for conveying the raw material into the mold, wherein the second heating element is fitted and covered on the outside or inside of the feed tube assembly, or embedded in the side wall of the feed tube assembly.

[0010] In a preferred embodiment of the carbon rod preparation system described above, the preparation system further includes a quantitative injection device for driving the raw materials in the feed tube assembly to be injected into the mold in a preset amount.

[0011] In a preferred embodiment of the carbon rod preparation system described above, the quantitative injection device includes a screw, the actual injection amount of the raw material is determined by controlling the forward distance of the screw, and the raw material in the feed tube assembly is injected into the mold according to a preset amount by the screw; or, the quantitative injection device includes a screw and a weighing device, the actual injection amount of the raw material is determined by the weighing device, and the raw material in the feed tube assembly is injected into the mold according to a preset amount by the screw.

[0012] In a preferred embodiment of the carbon rod preparation system described above, the preparation system further includes a pressing device for pressing and shaping the raw material in the mold cavity.

[0013] In a preferred embodiment of the above-described carbon rod preparation system, the preparation system further includes a turntable, the mold is arranged on the turntable and can rotate with the turntable, the mold includes a first mold and at least one second mold; the pressing device includes a first pressing part, which presses and shapes the raw materials in the first mold and the second mold by the pressing and resetting action of the first pressing part and the rotation of the turntable; or, the pressing device includes a first pressing part and at least one second pressing part, which presses and shapes the raw materials in the first mold by the pressing action of the first pressing part, and presses and shapes the raw materials in the second mold by the rotation of the turntable and the pressing action of the second pressing part.

[0014] In a preferred embodiment of the carbon rod preparation system described above, the mold further includes a cooling structure that fits and covers the outside or inside of the mold cavity, or is embedded in the side wall of the mold cavity, for independently cooling the raw materials in each mold cavity.

[0015] In a preferred embodiment of the carbon rod preparation system described above, the preparation system further includes a demolding mechanism for ejecting the shaped carbon rod product from the mold cavity; and / or, the preparation system further includes a conveying mechanism for grabbing the shaped carbon rod product and transferring it to a collection area.

[0016] In a second aspect, the present invention also provides a method for preparing a carbon rod, comprising: mixing carbon powder and a hot-melt binder in a predetermined ratio to form a mixed raw material; injecting a predetermined amount of the mixed raw material into a mold cavity; independently heating the mixed raw material in each mold cavity by arranging a first heating element on each independent mold cavity, which covers and adheres to the outside or inside of the mold cavity, or is embedded in the side wall of the mold cavity, so that the hot-melt binder melts and combines with the carbon powder to solidify and form a carbon rod; and removing the solidified carbon rod from the mold cavity to complete the preparation of the carbon rod.

[0017] In a preferred embodiment of the above-mentioned method for preparing carbon rods, the step of "injecting a preset amount of the mixed raw material into the mold cavity" further includes: preheating the preset amount of the mixed raw material to a first preset temperature while or before conveying the preset amount of the mixed raw material; and injecting the preheated preset amount of the mixed raw material into the mold cavity; wherein the first preset temperature is 50°C to 150°C.

[0018] In a preferred embodiment of the above-mentioned method for preparing carbon rods, the step of "injecting the preheated preset amount of the mixed raw material into the mold cavity" further includes: injecting the preheated preset amount of the mixed raw material into the mold cavity by means of screw quantitative injection or weighing injection.

[0019] In a preferred embodiment of the above-mentioned method for preparing carbon rods, a pressing device is included. After the step of "injecting the preheated preset amount of the mixed raw material into the cavity of the mold", the method further includes: compacting and shaping the mixed raw material in the cavity of the mold by means of the pressing device.

[0020] In a preferred embodiment of the above-mentioned method for preparing carbon rods, a turntable is included, the mold is arranged on the turntable and can rotate with the turntable, the mold includes a first mold and at least one second mold, the clamping device includes a first clamping part, and the step "compacting and shaping the mixed raw material in the mold cavity by means of the clamping device" further includes: compacting and shaping the mixed raw material in the first mold cavity by means of the first clamping part of the clamping device, and then removing the first clamping part from the first mold cavity and resetting it; rotating the first mold from the injection station to the heating station by means of the turntable, and rotating the second mold to the injection station; compacting and shaping the mixed raw material in the second mold cavity by means of the first clamping part of the clamping device, and then removing the first clamping part from the second mold cavity and resetting it.

[0021] In a preferred embodiment of the above-mentioned method for preparing carbon rods, a turntable is included, the mold is arranged on the turntable and can rotate with the turntable, the mold includes a first mold and at least one second mold, the clamping device includes a first clamping part and at least one second clamping part, and the step "compacting and shaping the mixed raw material in the mold cavity by the clamping device" further includes: compacting and shaping the mixed raw material in the first mold cavity by the first clamping part of the clamping device; rotating the first mold and the first clamping part from the injection station to the heating station by the turntable, and rotating the second mold to the injection station; compacting and shaping the mixed raw material in the second mold cavity by the second clamping part of the clamping device; and rotating the second mold and the second clamping part from the injection station to the heating station by the turntable.

[0022] In a preferred embodiment of the above-mentioned method for preparing carbon rods, the step "by arranging heating elements that cover and adhere to the outside or inside of the mold cavity, or embedding them into the sidewall of the mold cavity, independently heating the mixed raw materials in each mold cavity, so that the hot-melt binder melts and combines with the carbon powder to solidify and form a carbon rod" further includes: heating the mixed raw materials in the first mold cavity to a second preset temperature and continuing for a first preset time through the heating elements, so that the hot-melt binder melts and combines with the carbon powder to solidify and form a carbon rod; wherein the second preset temperature is adjustable in the range of 0°C to 300°C, and the first preset time is 60 seconds to 300 seconds.

[0023] In a preferred embodiment of the above-mentioned method for preparing carbon rods, after the step "heating the mixed raw materials in the first mold cavity to a second preset temperature and continuing for a first preset time through the heating element, so that the hot melt binder melts and combines with the carbon powder to solidify and form a carbon rod", the method further includes: rotating the first mold from the heating station to the cooling station through the turntable; and forcibly cooling the formed carbon rod by arranging cooling structures that cover and adhere to the outside or inside of the mold cavity or are embedded in the side wall of the mold cavity on each independent mold cavity, so that it can be fully shaped and the temperature can be reduced for demolding.

[0024] In a preferred embodiment of the above-mentioned method for preparing carbon rods, the step of "removing the solidified carbon rod from the mold cavity to complete the preparation of carbon rods" further includes: ejecting the shaped carbon rod product from the first mold cavity through a demolding mechanism; and grabbing the shaped carbon rod product through a conveying mechanism and transferring it to a collection area.

[0025] By employing the above technical solution, this invention tightly integrates the heating element (first heating element) with each individual mold cavity (fitting and covering or embedding it into the sidewall), thereby achieving miniaturization and precision of the heating target. Through this independent, localized heating method, the system can heat only the single mold currently being formed, avoiding the large amount of ineffective heat load generated by heating a large furnace space, a large amount of air, and molds not currently being heated. This directly solves the core problem of "huge ineffective heat load and low energy efficiency" mentioned in the background art, achieving energy saving and consumption reduction. Simultaneously, independent and precise heating lays the foundation for accurately controlling the heating temperature and time of each mold (as described in subsequent claims, the temperature range and time are adjustable), and combined with precise metering injection and pressing and shaping steps, effectively improves the consistency of carbon rod product performance and production efficiency. Attached Figure Description

[0026] The preferred embodiments of the present invention are described below with reference to the accompanying drawings, in which: Figure 1 This is a schematic diagram of some parts of the carbon rod preparation system of the present invention; Figure 2 This is an assembly diagram of the top of the mold, clamping device, and demolding mechanism; Figure 3 It is an exploded view of the top of the mold, clamping device, and demolding mechanism; Figure 4 This is a front view of the top of the mold, clamping device, and demolding mechanism; Figure 5 This is a first sectional view of the top of the mold, clamping device, and demolding mechanism, in which... Figure 5 yes Figure 4 AA in the middle; Figure 6 This is a right view of the top of the mold, clamping device, and demolding mechanism; Figure 7 This is a second sectional view of the top of the mold, clamping device, and demolding mechanism, in which... Figure 7 yes Figure 6 BB in the middle; Figure 8 This is a top view of the mold; Figure 9 This is a flowchart of the main process for preparing the carbon rod of the present invention; Figure 10 This is a flowchart of step S2; Figure 11 This is a flowchart of step S22; Figure 12 This is a flowchart of the first implementation method of step S23; Figure 13 This is a flowchart of the second implementation method of step S23; Figure 14 This is a flowchart of step S3; Figure 15 This is a flowchart of steps SA and SB; Figure 16 This is the flowchart for step S4.

[0027] List of reference numerals in the attached diagram: 1. Preparation system; 11. Mold; 111. First heating element; 112. Cooling structure; 113. Cavity; 114. Demolding hole; 12. Second heating element; 13. Material tube assembly; 14. Clamping device; 15. Turntable; 16. Demolding mechanism; 161. Ejector pin; 17. Hopper. Detailed Implementation

[0028] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the invention and are not intended to limit the scope of protection of the invention. Those skilled in the art can make adjustments as needed to adapt to specific applications.

[0029] It should be noted that in the description of this invention, the terms "upper," "lower," "left," "right," "front," and "rear," etc., indicating directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "connected" should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0031] Example 1 like Figures 1-8 As shown, to address the problems of high ineffective heat load and low energy utilization efficiency in the existing activated carbon filter preparation process, the carbon rod preparation system 1 of the present invention includes: The mold 11 includes a cavity 113 formed inside the mold 11 for containing the raw materials required for preparing carbon rods; a first heating element 111 is fitted and covered to the outside or inside of the cavity 113 of the mold 11, or embedded in the side wall of the cavity 113 of the mold 11, for independently heating the raw materials in each cavity 113 of the mold 11; the mold 11 is provided with a demolding hole 114. Each mold 11 may include one cavity 113, and the first heating element 111 independently heats the raw materials inside this one cavity 113. Alternatively, each mold 11 may include multiple cavities 113, and the first heating element 111 heats multiple cavities 113.

[0032] The second heating element 12 is used to preheat the raw material before it is injected into the cavity 113 of the mold 11.

[0033] The feed tube assembly 13 is used to convey raw materials into the mold 11. The second heating element 12 is attached to the outside or inside of the feed tube assembly 13, or embedded in the side wall of the feed tube assembly 13. A hopper 17 is provided at the connection between the feed tube assembly 13 and the mold 11.

[0034] A metering injection device (not shown in the figure) is used to drive the raw material in the feed tube assembly 13 to inject into the mold 11 according to a preset amount. The metering injection device includes a screw, and the actual injection amount of the raw material is determined by controlling the forward distance of the screw, and the raw material in the feed tube assembly 13 is driven into the mold 11 according to the preset amount by the screw; or, the metering injection device includes a screw and a weighing device, and the actual injection amount of the raw material is determined by the weighing device, and the raw material in the feed tube assembly 13 is driven into the mold 11 according to the preset amount by the screw.

[0035] The pressing device 14 is used to press and shape the raw material in the cavity 113 of the mold 11.

[0036] A turntable 15 is provided, and a mold 11 is arranged on the turntable 15 and can rotate with the turntable 15. The mold 11 includes a first mold 11 and at least one second mold 11. The pressing device 14 includes a first pressing part, which presses and shapes the raw materials in the first mold 11 and the second mold 11 by the pressing and resetting action of the first pressing part and the rotation of the turntable 15. Alternatively, the pressing device 14 includes a first pressing part and at least one second pressing part, which presses and shapes the raw materials in the first mold 11 by the pressing action of the first pressing part, and presses and shapes the raw materials in the second mold 11 by the rotation of the turntable 15 and the pressing action of the second pressing part.

[0037] The cooling structure 112 is fitted and covered on the outside or inside of the cavity 113 of the mold 11, or embedded in the side wall of the cavity 113 of the mold 11, for independently cooling the raw material in each cavity 113 of the mold 11. The cooling structure 112 can be a cooling water channel.

[0038] The demolding mechanism 16 is used to eject the molded carbon rod product from the cavity 113 of the mold 11. The top of the demolding mechanism 16 is provided with an ejector pin 161, which can extend into the cavity 113 of the mold 11 and eject the carbon rod.

[0039] A conveying mechanism (not shown in the figure) is used to grab the shaped charcoal briquette products and transfer them to the collection area.

[0040] In the above-described embodiment, the mixed raw material is preheated to a preset temperature (e.g., 50°C to 150°C) by the second heating element 12 integrated thereon when passing through the feed tube assembly 13; then, the metering injection device (by controlling the screw advance distance or in conjunction with a weighing device) accurately measures the preset amount of preheated raw material and injects it into the cavity 113 of the mold 11 by driving the screw.

[0041] After injection, the system enters the compaction, shaping, and curing stage. The mold 11, injected with the raw material, is driven by the turntable 15 and cooperates with the compaction device 14 (such as the first compaction part) to complete the compaction action. The turntable 15 can be designed as a multi-station structure, so that while one mold 11 is being injected and compacted, another mold 11 is being moved to the next station. Each cavity 113 of the mold 11 independently integrates a first heating element 111. At the heating station, this heating element can independently and precisely heat the raw material inside the cavity to a second preset temperature (e.g., adjustable within the range of 0-300℃) and maintain it for a specific time (e.g., 60-300 seconds), causing the binder in the raw material to melt and combine with the carbon powder to solidify and form the desired shape.

[0042] After curing, the turntable 15 rotates the mold 11 to the cooling station. The cooling structure 112, which is also integrated into the cavity 113 of the mold 11, independently and forcibly cools the formed carbon rod to ensure it is fully shaped and easy to process later. Finally, at the demolding station, the demolding mechanism 16 ejects the cooled formed carbon rod from the cavity 113 of the mold 11 through the demolding hole 114 via the ejector pin 161. The rod is then picked up by a conveying mechanism (such as a robot) and transferred to the collection area, completing the preparation cycle of a single carbon rod product.

[0043] The advantages of the above-described implementation method are as follows: Through the innovative design of "integrating heating elements on the independent mold cavity 113," the core problem of "huge ineffective heat load and low energy efficiency" caused by the overall heating of the furnace in traditional sintering processes is fundamentally solved. It achieves independent, localized heating for each molding unit, thereby significantly reducing energy consumption. Simultaneously, this independent and controllable heating method lays the foundation for precise control of subsequent processes. Combined with precise quantitative injection and a continuous production process driven by a multi-station turntable 15 (integrating pressing, heating, cooling, and demolding processes), it not only achieves energy saving and consumption reduction but also significantly improves the consistency and controllability of carbon rod products in terms of basis weight, density, and performance, and significantly shortens the production cycle, comprehensively realizing high efficiency, energy saving, and high quality in the carbon rod preparation process.

[0044] Furthermore, regarding the quantitative injection device, those skilled in the art can choose other common devices, such as stepper motors and push rods, or other devices capable of achieving the same function; this invention does not impose specific limitations in this regard. Those skilled in the art can also choose schemes that include or do not include a weighing device; these forms are all within the scope of protection of this invention. Additionally, regarding the arrangement of the clamping device 14, those skilled in the art can choose to provide only one first clamping part to clamp the raw materials in different molds 11, or they can provide one clamping part corresponding to each mold 11, or set the number of clamping parts and molds 11 to other quantities; this invention does not impose specific limitations in this regard, and these forms are all within the scope of protection of this invention.

[0045] Example 2 This invention also provides a method for preparing carbon rods, such as... Figures 9-16 As shown, it includes: S1. Take carbon powder and hot melt binder and mix them evenly in a predetermined ratio to form a mixed raw material; S2. Inject the preset amount of mixed raw materials into the mold cavity; S3. By arranging a first heating element on each independent mold cavity and covering and adhering to the outside or inside of the mold cavity, or embedding it into the side wall of the mold cavity, the mixed raw materials in each mold cavity are heated independently, so that the hot melt binder melts and combines with the carbon powder to solidify and form a carbon rod. S4. Remove the solidified carbon rod from the mold cavity to complete the carbon rod preparation.

[0046] Of the above steps, step S2 further includes: S21. While or before conveying the preset amount of mixed raw materials, preheat the preset amount of mixed raw materials to a first preset temperature; S22. Inject the preheated, pre-calculated amount of mixed raw material into the mold cavity; The first preset temperature is 50℃ to 150℃.

[0047] Step S22 further includes: S221. The preheated, pre-set amount of mixed raw materials is injected into the mold cavity by screw quantitative injection or weighing injection.

[0048] Step S22 is followed by: S23. The mixed raw materials in the mold cavity are compacted and shaped by a pressing device; Step S23 further includes: S231. The mixed raw material in the first mold cavity is compacted and shaped by the first pressing part of the pressing device, and then the first pressing part is pulled out of the first mold cavity and reset. S232. The first mold is rotated from the injection station to the heating station by a turntable, and the second mold is rotated to the injection station. S233. The mixed raw material in the second mold cavity is compacted and shaped by the first pressing part of the pressing device, and then the first pressing part is pulled out of the second mold cavity and reset.

[0049] Alternatively, step S23 may further include: S234. The mixed raw material in the first mold cavity is compacted and shaped by the first pressing part of the pressing device; S235. The mixed raw material in the second mold cavity is compacted and shaped by the second clamping part of the clamping device; S236. The second mold and the second clamping part are rotated from the injection station to the heating station by a turntable.

[0050] Step S3 further includes: S31. The mixed raw materials in the first mold cavity are heated to a second preset temperature and maintained for a first preset time by a heating element, so that the hot melt binder melts and combines with carbon powder to solidify and form a carbon rod. The second preset temperature is adjustable within the range of 0℃ to 300℃, and the first preset time is 60 seconds to 300 seconds.

[0051] Step S3 is followed by: SA, the first mold is rotated from the heating station to the cooling station using a turntable; SB: By arranging cooling structures on each independent mold cavity that cover and adhere to the outside or inside of the mold cavity, or are embedded in the side wall of the mold cavity, the formed carbon rod is forced to cool, so that it can be fully shaped and the temperature can be reduced for demolding.

[0052] Step S4 further includes: S41. The molded carbon rod product is ejected from the first mold cavity by the demolding mechanism; S42. The shaped charcoal rods are picked up by the conveying mechanism and transferred to the collection area.

[0053] In the above-described embodiment, firstly (S1), carbon powder and hot-melt binder are mixed evenly in a predetermined ratio to form a mixed raw material. Then, this raw material enters a precisely controlled injection cycle. Before or during injection (S21), a predetermined amount of raw material is preheated to a suitable temperature (e.g., 50-150°C) by an independent preheating system (e.g., heating the feed pipe via a second heating element). Next (S22 / S221), precise metering is performed using a screw metering method or a combination of screw and weighing, and the preheated predetermined amount of raw material is injected into the mold cavity.

[0054] After injection, the system enters the compaction and multi-station transfer stage. The material within the mold cavity is compacted using a clamping device (S23). This process is cleverly integrated with mold transfer, with a turntable as its core component. In a typical multi-station configuration, after the injected mold (first mold) is clamped and shaped, the turntable rotates it from the injection station to the next process (such as the heating station), while simultaneously rotating a new empty mold (second mold) to the injection station for a new round of injection and clamping (S231-S233). The entire system can have multiple clamping units working together to achieve simultaneous clamping, shaping, and transfer of multiple molds (S234-S236), thus creating a continuous and parallel production cycle.

[0055] The core curing step is independent heating (S3 / S31). At the heating station, a first heating element (which can be attached or embedded) integrated into each individual mold cavity independently and precisely heats the mixed raw materials within each mold. This allows the binder to melt and combine with the carbon powder within a specific temperature range (e.g., adjustable from 0-300℃) and a specific time (e.g., 60-300 seconds), thereby curing and shaping the carbon rod. This method of heating individual molds avoids the enormous energy waste associated with heating the entire furnace in traditional processes.

[0056] After curing, the shaped charcoal rods undergo cooling, demolding, and collection. First (SA / SB), the mold rotates to the cooling station driven by a turntable. The charcoal rods are then subjected to independent forced cooling using a cooling structure integrated into the mold cavity to fully set their shape and reduce their temperature. Finally (S4 / S41-S42), at the demolding station, a demolding mechanism (such as an ejector pin) pushes the cooled charcoal rods out of the mold. A conveying mechanism (such as a robotic arm) then picks them up and transfers them to the collection area, completing the production of a single product.

[0057] The advantages of the above implementation method are as follows: By integrating heating and cooling structures on independent mold cavities, the core problem of "huge ineffective heat load and low energy efficiency" caused by prolonged heating of the entire furnace (containing a large number of molds and air) in traditional "sintering" processes is fundamentally solved. This design achieves localized, independent, and precise heating and cooling for each mold, thereby significantly reducing energy consumption during curing and shaping. Simultaneously, independent control lays the foundation for process precision. Combined with precise quantitative injection (screw metering or weighing) and a multi-station rotary table driven continuous production process (integrating raw material preheating, injection, pressing, independent heating, independent cooling, demolding, and collection), significant energy savings and consumption reductions are achieved while simultaneously improving the consistency and controllability of carbon rod products in terms of basis weight, density, and physical properties. Furthermore, the parallel operation of multiple stations significantly shortens the single-piece production cycle, fully realizing efficient, energy-saving, high-quality, and automated carbon rod preparation.

[0058] Those skilled in the art will understand that the above-described carbon rod fabrication system also includes other known structures, such as processors, controllers, and memories. These memories include, but are not limited to, random access memory (RAM), flash memory, read-only memory (ROM), programmable read-only memory (PROM), volatile memory, non-volatile memory, serial memory, parallel memory, or registers. Processors include, but are not limited to, CPLD / FPGA, DSP, ARM processors, and MIPS processors. To avoid unnecessarily obscuring the embodiments of this disclosure, these known structures are not shown in the accompanying drawings.

[0059] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A carbon rod preparation system (1), characterized in that, Includes a mold (11), said mold (11) comprising: A cavity (113) is formed inside the mold (11) to hold the raw materials required for preparing carbon rods; The first heating element (111) is fitted and covered on the outside or inside of the cavity (113) of the mold (11), or embedded in the side wall of the cavity (113) of the mold (11), for independently heating the raw materials in each cavity (113) of the mold (11).

2. The carbon rod preparation system (1) according to claim 1, characterized in that, The preparation system (1) further includes a second heating element (12) for preheating the raw material before it is injected into the cavity (113) of the mold (11).

3. The carbon rod preparation system (1) according to claim 2, characterized in that, The preparation system (1) further includes a feed tube assembly (13) for conveying the raw material into the mold (11), wherein the second heating element (12) is fitted and covered on the outside or inside of the feed tube assembly (13), or embedded in the side wall of the feed tube assembly (13).

4. The carbon rod preparation system (1) according to claim 1, characterized in that, The preparation system (1) also includes a quantitative injection device for driving the raw materials in the material tube group (13) to be injected into the mold (11) in a preset amount.

5. The carbon rod preparation system (1) according to claim 4, characterized in that, The quantitative injection device includes a screw, and the actual injection amount of the raw material is determined by controlling the forward distance of the screw. The raw material in the material tube assembly (13) is injected into the mold (11) according to a preset amount by driving the screw. Alternatively, the quantitative injection device includes a screw and a weighing device. The actual injection amount of the raw material is determined by the weighing device, and the raw material in the material tube assembly (13) is injected into the mold (11) according to a preset amount by the screw.

6. The carbon rod preparation system (1) according to claim 1, characterized in that, The preparation system (1) also includes a pressing device (14) for pressing and shaping the raw material in the cavity (113) of the mold (11).

7. The carbon rod preparation system (1) according to claim 6, characterized in that, The preparation system (1) further includes a turntable (15), the mold (11) is arranged on the turntable (15) and can rotate with the turntable (15), the mold (11) includes a first mold (11) and at least one second mold (11). The pressing device (14) includes a first pressing part, which presses and shapes the raw materials in the first mold (11) and the second mold (11) by the pressing and resetting action of the first pressing part and the rotation of the turntable (15); Alternatively, the pressing device (14) includes a first pressing part and at least one second pressing part. The pressing action of the first pressing part presses and shapes the raw material in the first mold (11), and the pressing action of the turntable (15) and the pressing action of the second pressing part presses and shapes the raw material in the second mold (11).

8. The carbon rod preparation system (1) according to claim 1, characterized in that, The mold (11) also includes a cooling structure (112), which fits and covers the outside or inside of the cavity (113) of the mold (11), or is embedded in the side wall of the cavity (113) of the mold (11), for independently cooling the raw materials in each cavity (113) of the mold (11).

9. The carbon rod preparation system (1) according to claim 1, characterized in that, The preparation system (1) also includes a demolding mechanism (16) for ejecting the molded carbon rod product from the cavity (113) of the mold (11); And / or, the preparation system (1) further includes a conveying mechanism for grabbing the shaped carbon rod product and transferring it to the collection area.

10. A method for preparing carbon rods, characterized in that, include: Take carbon powder and hot-melt binder and mix them evenly in a predetermined ratio to form a mixed raw material; A predetermined amount of the mixed raw material is injected into the mold cavity; By arranging a first heating element on each independent mold cavity, which is wrapped and attached to the outside or inside of the mold cavity, or embedded in the side wall of the mold cavity, the mixed raw materials in each mold cavity are independently heated, so that the hot melt binder melts and combines with the carbon powder to solidify and form a carbon rod; The solidified carbon rod is removed from the mold cavity to complete the carbon rod preparation.

11. The method for preparing carbon rods according to claim 10, characterized in that, The step "injecting a preset amount of the mixed raw material into the mold cavity" further includes: While or before delivering the preset amount of the mixed raw material, the preset amount of the mixed raw material is preheated to a first preset temperature; The preheated, preset amount of the mixed raw material is injected into the mold cavity; The first preset temperature is between 50°C and 150°C.

12. The method for preparing carbon rods according to claim 11, characterized in that, The step "injecting the preheated, preset amount of the mixed raw material into the mold cavity" further includes: The preheated, preset amount of the mixed raw material is injected into the mold cavity by screw injection or weighing injection.

13. The method for preparing carbon rods according to claim 11, characterized in that, Including a clamping device, the step of "injecting the preheated, preset amount of the mixed raw material into the cavity of the mold" further includes: The compaction device compacts and shapes the mixed raw materials in the mold cavity.

14. The method for preparing carbon rods according to claim 13, characterized in that, The device includes a turntable, the mold is arranged on the turntable and can rotate with the turntable, the mold includes a first mold and at least one second mold, the clamping device includes a first clamping part, and the step "compacting and shaping the mixed raw material in the mold cavity by means of the clamping device" further includes: The first pressing part of the pressing device compacts and shapes the mixed raw material in the first mold cavity, and then the first pressing part is pulled out of the first mold cavity and reset. The first mold is rotated from the injection station to the heating station via the turntable, and the second mold is rotated to the injection station. The first pressing part of the pressing device compacts and shapes the mixed raw material in the second mold cavity, and then the first pressing part is pulled out of the second mold cavity and reset.

15. The method for preparing carbon rods according to claim 13, characterized in that, The device includes a turntable, the mold is arranged on the turntable and can rotate with the turntable, the mold includes a first mold and at least one second mold, the clamping device includes a first clamping part and at least one second clamping part, and the step "compacting and shaping the mixed raw material in the mold cavity by means of the clamping device" further includes: The first pressing part of the pressing device compacts and shapes the mixed raw material in the first mold cavity; The first mold and the first clamping part are rotated from the injection station to the heating station via the turntable, and the second mold is rotated to the injection station; The mixed raw material in the second mold cavity is compacted and shaped by the second pressing part of the pressing device; The second mold and the two clamping parts are rotated from the injection station to the heating station via the turntable.

16. The method for preparing carbon rods according to claim 14 or 15, characterized in that, The step "by arranging heating elements that cover and adhere to the outside or inside of the mold cavity, or embed them into the sidewall of the mold cavity, to independently heat the mixed raw materials in each mold cavity, so that the hot-melt binder melts and combines with the carbon powder to solidify and form a carbon rod" further includes: The heating element heats the mixed raw materials in the first mold cavity to a second preset temperature and continues for a first preset time, so that the hot melt binder melts and combines with the carbon powder to solidify and form a carbon rod. The second preset temperature is adjustable within the range of 0°C to 300°C, and the first preset time is 60 seconds to 300 seconds.

17. The method for preparing carbon rods according to claim 16, characterized in that, The step "heating the mixed raw materials in the first mold cavity to a second preset temperature and maintaining it for a first preset time through the heating element, so that the hot melt binder melts and combines with the carbon powder to solidify and form a carbon rod" further includes: The first mold is rotated from the heating station to the cooling station via the turntable; The formed carbon rod is forced to cool by arranging cooling structures on each individual mold cavity that cover and fit the outside or inside of the mold cavity, or are embedded in the side wall of the mold cavity, so that it can be fully shaped and the temperature can be reduced for demolding.

18. The method for preparing carbon rods according to claim 17, characterized in that, The step "removing the solidified carbon rod from the mold cavity to complete the carbon rod preparation" further includes: The molded carbon rod product is ejected from the first mold cavity by the demolding mechanism; The shaped charcoal rods are picked up by a transport mechanism and transferred to the collection area.

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