Continuous Molded Emitter Extrusion for Irrigation Hose Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current drip irrigation systems face inefficiencies in water and fertilizer use, high labor and energy costs, and uneven water distribution, particularly on uneven terrain, due to limitations in emitter technology that restrict production speed and emitter definition.
Innovation Solution
A method of extruding a continuous molded emitter on a substrate, allowing for higher production speeds and improved emitter definition by utilizing a cooler substrate for structural support, enabling increased line speed and efficient lamination of the emitter units into the hose.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flow path is extruded as a bead and formed into a flow path using a rotary mold, then the emitter units are formed, but the production speed is limited because the flow path cannot be extruded faster or it will lose its definition and structural integrity
Solution Approach 1:
The flow path is segmented into discrete emitter units along its length, with each emitter unit having distinct inlet and outlet openings. This segmentation allows the flow path to be formed as a continuous structure that maintains structural integrity at higher extrusion speeds while still providing discrete emission points for uniform water distribution
Solution Approach 2:
The extrusion parameters are optimized to allow higher line speeds while maintaining emitter definition. The flow path material and extrusion conditions are controlled to prevent loss of definition at increased speeds, enabling production speed increases of at least 100% compared to prior art methods
2Strength
If the flow path relies on its own structural integrity during extrusion, then it can maintain its shape, but the extrusion speed must be kept low to prevent loss of definition
Solution Approach 1:
The flow path is formed as a composite structure with specific material properties that provide both structural integrity and flexibility. The material composition and cross-sectional geometry are designed to maintain shape stability during high-speed extrusion while allowing the flow path to be formed into complex emitter configurations
3Ease of operation
If discrete emitters are installed internally or externally to the hose, then water flow can be regulated, but labor and energy costs increase
Solution Approach 1:
The flow path is merged with the hose as a single integrated structure, with the flow path embedded within the hose wall. This eliminates the need for separate installation of discrete emitters and reduces labor and energy costs while maintaining water flow regulation capabilities through the integrated emitter units
Solution Approach 2:
The hose structure serves multiple functions: it provides water transport, structural support, and integrated water distribution through the embedded flow path. This multi-functionality eliminates the need for separate emitter installation steps and reduces overall system complexity
4Quantity of substance
If flood and sprinkler systems are used for irrigation, then water can be applied, but uniformity of water application on steep or uneven terrain deteriorates
Solution Approach 1:
The flow path provides localized water distribution through closely spaced emitter units along its length. This local quality of water delivery ensures uniform application even on uneven terrain, as each emitter unit delivers water directly to the ground at its specific location, compensating for terrain variations
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 enhances the efficiency and uniformity of water application, reduces production costs, and allows for more defined emitter units, addressing the limitations of existing systems by increasing line speed by at least 100% and improving emitter effectiveness.
Implementation Method 1
allowing the substrate to cool to a second temperature. The second temperature is less than 160° F.
Implementation Method 2
A continuous flow path is extruded. The flow path has a plurality of emitter units. The flow path is extruded on the substrate
Implementation Method 3
A hose, having an inner wall, is extruded and the continuous strip member is operatively connected to the inner wall
Data Source
AI summary
An irrigation hose (10) includes a continuous strip member (27). The continuous strip member (27) is formed by extruding a substrate (20) and allowing the substrate (20) to cool. Then a flow path (25) is extruded on the substrate (20). The continuous strip member (27) is then operatively connected to the inner wall 10a of the irrigation hose (10).