Automatic processing method using an automatic processing apparatus
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Solution Overview
Problem
Current thawing methods, such as water baths and microwaves, result in temperature gradients and varying thawing times, which can damage materials and reduce processing efficiency, especially for two-component sealants that require fast freezing and thawing to maintain usability.
Innovation Solution
An automatic processing method using a closed-loop system with a processing medium reservoir and container, where the medium is continuously circulated to maintain a constant temperature, ensuring uniform processing and preventing overheating or undercooling, and a holding device for precise placement of non-hermetically sealed containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water bath thawing is used with the subject material placed in a container, then the thawing process can be performed, but the water level changes when differently sized subject materials are placed, making exact relative placement difficult and water may flow into non-hermetically closed containers
Solution Approach 1:
The system is divided into two separate containers: a processing medium reservoir and a processing container. This segmentation allows the processing medium level in the processing container to be independent of the subject material size, as the medium is continuously supplied from the reservoir. The inlet opening and outlet opening create a controlled flow path that maintains constant level regardless of container contents.
Solution Approach 2:
The continuous circulation system provides feedback control for the processing medium level. When the level rises, overflow occurs through the outlet opening; when the level drops, more medium flows in through the inlet opening. This automatic feedback mechanism maintains a constant processing medium level without manual intervention, solving the water level control precision problem.
2Reliability
If the water bath temperature is limited to the target temperature of the subject material, then overheating is avoided, but the thawing time increases and processing efficiency decreases
Solution Approach 1:
The system maintains continuous circulation of the processing medium through the processing container throughout the processing cycle. This continuous action ensures constant heat transfer efficiency, allowing the processing medium to be maintained at a higher temperature while the subject material reaches the target temperature uniformly through sustained thermal exposure rather than intermittent heating.
Solution Approach 2:
The processing medium acts as an intermediary that can be maintained at a temperature higher than the subject material's target temperature. The continuous circulation ensures that heat is transferred gradually and uniformly to the subject material, preventing direct thermal shock and overheating while maintaining high processing efficiency through the temperature gradient between medium and material.
3Productivity
If microwave thawing is used, then thawing speed increases, but significant temperature gradients and variations occur within the subject material, leading to varying thawing times at different locations and potential quality damage
Solution Approach 1:
The system applies uniform thermal conditions throughout the processing container by continuously circulating the processing medium around the subject material. This ensures that all surfaces of the subject material are exposed to the same temperature environment, creating uniform heat transfer conditions. The constant processing medium level and continuous circulation eliminate local hot spots and temperature gradients that occur in microwave thawing.
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 method enables fast, uniform, and efficient processing of materials without overheating or undercooling, extending the application time for two-component sealants and preventing contamination, while allowing for precise temperature control and handling of differently sized containers.
Implementation Method 1
continuously transporting, via a transporting device, the processing medium, during a processing time, from the processing medium reservoir into the processing container
Implementation Method 2
The processing medium enters the processing container via an inlet opening and exits the processing container by overflowing via an outlet opening, such that a fixed processing medium level is present within the processing container during the processing cycle
Implementation Method 3
a heating device within the processing medium reservoir... bringing the processing medium within the processing medium reservoir to a predefined temperature
Implementation Method 4
a cooling device within the processing medium reservoir... bringing the processing medium within the processing medium reservoir to a predefined temperature
Implementation Method 5
ensuring uniform processing and preventing overheating or undercooling... continuous circulation to maintain a constant temperature
Data Source
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AI summary
A method (100) for automatically processing a subject material (200) and a corresponding automatic processing apparatus (10) for carrying out the method is provided. The method (100) comprises processing (101) a processing medium (19) within a processing medium reservoir (11) to predefined conditions, holding (102) the processing medium (19) within the processing medium reservoir (11) at the predefined conditions, arranging (103) the subject material (200) to be tempered relative to a processing container (12), such that the subject material (200) at least partially is located within the processing container (12), and starting (104) a tempering cycle. The method then comprises continuously transporting (105), via a pump (13), the processing medium (19), during a processing time, from the processing medium reservoir (11) into the processing container (12), wherein the processing medium (19) enters the processing container (12) via an inlet opening (16) and exits the processing container (12) by overflowing via an outlet opening (17), such that a fixed processing medium level (22) is present within the processing container (12) during the processing cycle, and removing (107) the processing medium (19) from the processing container (12) back into the processing medium reservoir (11) via the inlet opening (16) when the processing time is reached. The automatic processing process may, e.g., be a tempering process, or a galvanization process, or another process for treating a subject material (200) with a processing medium.