Continuous Hollow Tube Web Extrusion with Spacer Segments
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Solution Overview
Problem
Existing methods for producing small-sized tubing, such as capillary tubing and hollow fiber, face challenges in achieving uniformity of flow and managing multiple tubes due to the critical dependence on die cavity size, which affects the extrusion process and the formation of consistent tube shape.
Innovation Solution
A method involving an extrusion die with a specific arrangement of shims that define multiple cavities and orifices, allowing simultaneous dispensing of polymeric tubes and spacer segments, with alternating passageways to create a continuous web of interconnected tubes and spacer segments, enhancing uniform arrangement and heat transfer capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision dies are used for small-sized tubing extrusion, then uniform tube shape is achieved, but die passageway resistance becomes critical and difficult to control
Solution Approach 1:
The die is segmented into multiple cavities (first cavity, second cavity, third cavity) with separate passageways for different materials. This segmentation allows independent control of each cavity's flow characteristics, eliminating the need for complex resistance control in a single precision die while maintaining uniform tube shapes.
Solution Approach 2:
A connecting film is introduced as an intermediary element that bonds the tubes together. This connecting film is dispensed from a separate third cavity, allowing the die design to focus on uniform tube formation while the connecting film handles the bonding function, simplifying the overall die design.
2Productivity
If multiple small tubes are produced simultaneously, then productivity increases, but difficulty in managing multiple tubes increases
Solution Approach 1:
Multiple individual tubes are merged into a single continuous web structure through the connecting film. This combining approach maintains high productivity by producing multiple tubes simultaneously while simplifying handling, as the entire array can be managed as one integrated web rather than separate tubes.
Solution Approach 2:
The tubes are arranged in a two-dimensional web configuration rather than as separate three-dimensional objects. This dimensional change allows multiple tubes to be produced and handled in a planar format, making them easier to manage, transport, and process while maintaining high production rates.
3Adaptability or versatility
If tube wall is made permeable for mass transfer, then mass transfer capability is achieved, but structural integrity may be compromised
Solution Approach 1:
The web structure combines permeable tube walls for mass transfer with a continuous connecting film matrix for structural support. This composite approach allows the tube walls to be permeable for mass transfer applications while the connecting film provides overall structural integrity to the web assembly.
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
The solution enables the production of a continuous web with uniformly spaced, hollow polymeric tubes that provide high thermal conductivity and efficient heat transfer, addressing the challenges of uniformity and manageability in small-sized tubing production.
Implementation Method 1
dispensing first polymeric tubes from the first dispensing orifices while simultaneously dispensing spacer segments from the second dispensing orifices
Data Source
Figure 1~3
Figure 4~6
Figure 7A~7B
AI summary
A web. The web includes an array of discrete polymeric tubes; a plurality of spacer segments between at least a plurality of adjacent polymeric tubes; wherein polymeric tubes are hollow polymeric tubes; wherein the web is a continuous web.