Multi-Layer Composite Pipe Cooling for Production Speed
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Solution Overview
Problem
Current methods for producing multi-layer composite pipes are limited by slow production speeds, necessitating the development of a system that can enhance manufacturing efficiency.
Innovation Solution
A plant design where a metal tube is first formed with a weld seam, followed by the extrusion of a plastic inner pipe, which is then cooled before a plastic outer pipe is extruded, utilizing effective cooling methods such as ambient air or a cooling bath to expedite the process, and incorporating a squeezing device to prevent collapse and ensure airtight sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the inner pipe is extruded into the metal pipe and the outer pipe is extruded immediately after without cooling, then the production speed is maintained continuously, but the extrudate collapses and cannot be properly sealed
Solution Approach 1:
The patent applies preliminary cooling action by introducing the intermediate composite pipe into a cooling bath immediately after extrusion, before the outer pipe extrusion. This preliminary cooling hardens the inner pipe structure, enabling it to withstand subsequent processing and sealing operations without collapse, thus resolving the contradiction between continuous production and sealing quality.
2Productivity
If the intermediate composite pipe is cooled in a cooling bath, then the cooling speed increases and production efficiency improves, but the device complexity increases
Solution Approach 1:
The patent employs a cooling bath that utilizes ambient cooling or simple thermal conduction through the bath medium. The cooling system operates with minimal active components, allowing the intermediate composite pipe to cool passively while moving through the bath, thereby achieving rapid cooling without significantly increasing device complexity.
3Strength
If air is introduced into the extrudate to prevent collapse, then the structural integrity is maintained, but the sealing becomes more difficult
Solution Approach 1:
The patent performs preliminary cooling and hardening of the inner pipe structure before the sealing operation. This preliminary action removes the air trapped in the extrudate and establishes a rigid structure that can be sealed effectively, thus maintaining structural integrity while facilitating easier sealing.
4Temperature
If the metal pipe is used as the outer layer, then the heat dissipation is improved and cooling efficiency increases, but the production time for complete pipe assembly increases
Solution Approach 1:
The patent implements continuous extrusion of the inner pipe into the metal pipe and continuous cooling in the cooling bath, followed by immediate continuous extrusion of the outer pipe. This continuous process eliminates idle time between operations, maintaining high cooling efficiency while minimizing assembly time through uninterrupted production flow.
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 approach allows for significantly increased production speeds by effectively cooling the intermediate composite pipe, enabling rapid hardening and sealing, thus facilitating faster and more efficient production of multi-layer composite pipes.
Implementation Method 1
specifically in a first cooling device to allow the pipe to cool down... it is possible and preferred to pass the intermediate composite pipe through a cooling bath
Implementation Method 2
the metal pipe is on the outside. Metals are basically good conductors of heat, so they dissipate the heat introduced during extrusion to the outside
Implementation Method 3
In order to prevent the extrudate from collapsing, air is introduced into the ring-shaped extrudate via a nozzle in addition to the plastic. The still soft plastic is pressed from the inside against the metal pipe via this air due to a counter-pressure in the pipe
Data Source
AI summary
The plant (10) produces a composite pipe (12) with a plastic inner pipe (27), metal pipe (16) and plastic outer pipe (39). The metal pipe is produced in a pipe making machine (13) from a metal strip (14), welding the seam at the welding point (18). The inner pipe is then extruded into the metal pipe from an extrusion device. The combined pipe is cooled in a first cooler (30) before the outer pipe (36) is extruded onto it.