Continuous Pyrotechnic Mixing and Casting Process
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Solution Overview
Problem
Current batch processes for manufacturing large pyrotechnic objects are cumbersome and expensive due to the need for multiple discontinuous operations and formulation changes, which are difficult to implement efficiently and cost-effectively.
Innovation Solution
A continuous mixing and casting process using a co-rotating or contra-rotating single-screw or twin-screw mixing member that allows for variation of feed parameters such as constituent nature, flow rates, and residence time to achieve a pyrotechnic object with variable composition, enabling efficient formulation changes and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a discontinuous batch process is used to manufacture large pyrotechnic objects, then the manufacturing process is well-established and reliable, but the process becomes cumbersome and expensive when formulation changes are required
Solution Approach 1:
The patent applies continuous mixing and casting operations to replace discontinuous batch processes. The mixing member continuously mixes constituents while the casting device continuously pours the mixture into molds, eliminating the need to stop and restart operations for formulation changes. This continuous operation allows efficient implementation of multiple formulations without the cumbersome intermediate steps required in batch processes.
2Adaptability or versatility
If multiple successive batch operations are performed to achieve multi-composition loadings, then different formulations can be obtained, but the process becomes particularly cumbersome and expensive
Solution Approach 1:
The patent segments the casting process into multiple zones within continuous molds, where different portions of the mold receive different formulations during the same continuous operation. The casting device can pour different compositions into different zones of the mold simultaneously or sequentially without stopping the process, thereby achieving multi-composition loadings with a single continuous operation rather than multiple successive batch operations.
Solution Approach 2:
The patent employs dynamic control of the casting process where the formulation being poured can be changed during operation. The system dynamically adjusts which formulation is supplied to the mixing member and casting device at different times or to different zones, allowing flexible implementation of multiple compositions without requiring separate batch operations for each formulation.
3Manufacturing precision
If traditional batch mixing and casting is used, then thorough mixing under vacuum and temperature control is achieved, but the production efficiency is reduced and footprint is increased
Solution Approach 1:
The patent merges the mixing and casting operations into a single continuous integrated process. The mixing member and casting device operate together in sequence without interruption, combining what were previously separate batch operations into one continuous flow. This integration maintains thorough mixing quality while significantly improving production efficiency by eliminating the downtime between mixing and casting steps.
4Duration of action of stationary object
If batch processes are used for large pyrotechnic objects, then adequate mixing and cooking time is provided, but the manufacturing footprint and material usage are increased
Solution Approach 1:
The continuous process allows multiple formulations to be processed through the same mixing and casting equipment without interruption or idle time between batches. The system maintains continuous operation with adequate mixing and cooking time for each formulation while using the same physical equipment, thereby reducing the manufacturing footprint compared to having separate batch facilities for different formulations.
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 continuous process simplifies production, reduces costs, and enhances flexibility by allowing multiple formulations without intermediate cooking, while minimizing material usage and manufacturing footprint, and ensures reproducibility and safety through controlled composition gradients.
Implementation Method 1
a mixing member, of the co-rotating or contra-rotating single-screw or twin-screw type, which is suitable for mixing with transport of the different constituents of the pyrotechnic object being manufactured
Implementation Method 2
said mixing member being of the co-rotating or contra-rotating single-screw or twin-screw type, for mixing said different constituents in said mixing member, with progression within the structure of said mixing member
Implementation Method 3
a casting device, arranged at said at least one recovery opening of said mixing member, which is suitable for pouring the mixture obtained into a mold
Data Source
Figure 1
Figure 2A~2B
Figure 3A~5
AI summary
The present invention relates to a method (and associated device) for the continuous manufacturing of a pyrotechnic object (10, 20, 30, 40). This method is of the continuous mixing and pouring type. Characteristically, it is implemented with modification of the composition of the poured mixture. This method is particularly suitable for the manufacture of large pyrotechnic objects.