Composite Mat Cooling via Superheated Water Phase Transition
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Solution Overview
Problem
Existing manufacturing technologies for thermoplastic composite boards are energy-intensive and inefficient, particularly in the steps of heating, melting, forming, congealing, and cooling, and they often result in defects like steam-blows due to high moisture content and inadequate cooling processes.
Innovation Solution
A method involving a hot-pressing stage followed by a cold-pressing stage, with controlled pressure and temperature changes to rapidly heat and cool composite mats composed of paper and plastic fragments, using a processor to manage the platen operations and achieve a sudden temperature drop to congeal the plastic, while maintaining pressure to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heating and cooling methods are used for thermoplastic composite boards, then the plastic can be melted and congealed, but the processing time is extended and energy consumption increases
Solution Approach 1:
The patent utilizes the phase transition of water (from liquid to vapor) as a cooling mechanism. Water is introduced into the composite mat during hot-pressing, then rapidly vaporizes when the press is opened, providing instantaneous cooling that dramatically reduces processing time while lowering energy consumption compared to conventional gradual cooling methods
Solution Approach 2:
The patent employs periodic action by alternating between the closed hot-pressing phase and the open rapid-cooling phase. This cyclic process allows the composite mat to be heated under pressure, then quickly cooled upon opening, creating an efficient repeatable manufacturing cycle that improves productivity
2Manufacturing precision
If high moisture content is present in the composite mat during hot-pressing, then the material can be formed, but steam-blows and defects occur due to inadequate cooling control
Solution Approach 1:
The patent converts the harmful effect of high moisture content (which causes steam-blows) into a beneficial cooling mechanism. By controlling the hot-pressing parameters and then rapidly opening the press, the water vaporization that would normally cause defects is instead harnessed as an instantaneous cooling process that prevents steam-blows and improves product quality
Solution Approach 2:
The patent implements feedback control by monitoring the hot-pressing process parameters (temperature, pressure, time) and using this information to determine the optimal moment to open the press for rapid cooling. This controlled feedback mechanism ensures that cooling occurs at the precise moment when it provides maximum benefit while preventing defects
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 reduces processing time and energy consumption, prevents defects like steam-blows, and achieves the desired core temperature and caliper in the composite boards efficiently.
Implementation Method 1
one or more pairs of opposing hot-platens that are used in a hot-pressing stage... receipt of the first signal causing the one or more pairs of opposing hot-platens to compress and heat the composite mat
Implementation Method 2
heat and compress the composite mat at substantially a first pressure to superheat the water such that a temperature of the water remains above a boiling temperature of the water at a standard atmospheric pressure without the water changing from a liquid state to a gaseous state
Implementation Method 3
transmits a third signal to the one or more pairs of opposing hot-platens, receipt of the third signal causing the one or more pairs of opposing hot-platens to release the composite mat from the first pressure after the first time period, wherein releasing the composite mat causes the superheated water in the mat to change from a liquid state to a gaseous state
Implementation Method 4
transmits a fourth signal to the one or more pairs of opposing cold-platens, receipt of the fourth signal causing the one or more pairs of opposing cold-platens to compress and cool the composite mat for a second time period sufficient for the core of the composite mat to reach a second target temperature
Data Source
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AI summary
In accordance with some aspects of the present disclosure, a method (400) producing a composite board (100) comprising plastic and cellulose is described. The method includes transmitting a first signal to a pair of opposing hot-platens, receipt of the first signal causing the pair of opposing hot-platens (606, 608) to compress and heat a composite mat (610); transmitting a second signal to the pair of opposing hot-platens (606, 608), receipt of the second signal causing the pair of opposing hot-platens (606, 608) to heat and compress the composite mat (610) at substantially a first pressure for a first time period; transmitting a third signal to the pair of opposing hot-platens (606, 608), receipt of the third signal causing the pair of opposing hot-platens (606, 608) to release the composite mat (610) from the first pressure; and transmitting a fourth signal to a pair of opposing cold-platens, receipt of the fourth signal causing the pair of opposing cold-platens to compress and cool the composite mat (610).