Continuous Tubular Rod Forming with Overheated Steam Control
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Solution Overview
Problem
Existing methods for forming hollow acetate tubes using plasticizer and steam heat treatment face issues with water droplet formation, which negatively affect material quality and process consistency.
Innovation Solution
A forming apparatus and method utilizing a steam generator with fluid conduits and temperature/pressure control units to precisely manage overheated steam application, ensuring accurate temperature and pressure adjustments at injection sites, combined with air cooling to stabilize the tubular rod shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam heat treatment is used to form the tow material, then high and rapid heat transfer is achieved, but water droplets are created that negatively affect material quality and the forming process
Solution Approach 1:
The patent changes the physical parameters of the steam by controlling its temperature and pressure to achieve superheated steam. This parameter change prevents condensation and water droplet formation while maintaining high heat transfer rates, thereby resolving the contradiction between rapid heating and water droplet creation
Solution Approach 2:
The patent introduces an intermediary system comprising a steam generator, distribution system with fluid conduits, and temperature/pressure control units. This intermediary infrastructure enables precise control of steam properties to eliminate water droplets while preserving effective heat transfer
2Manufacturing precision
If steam is provided through a distribution system with multiple fluid conduits, then precise temperature and pressure control at injection sites is achieved, but device complexity increases
Solution Approach 1:
The patent segments the steam distribution system into multiple independent fluid conduits with individual temperature and pressure control units. This segmentation enables precise local control of steam parameters at different injection sites while maintaining manageable system complexity through modular design
Solution Approach 2:
The patent implements feedback control through temperature sensors and pressure sensors that continuously monitor steam conditions at injection sites and automatically adjust the steam generator output and control units. This feedback mechanism achieves high precision control while managing system complexity through automated regulation
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
Enhances control over the forming process, improving the quality and consistency of tubular rods by minimizing temperature and pressure losses, and ensuring precise shaping and hardening.
Implementation Method 1
a steam generator adapted to generate overheated steam, wherein the steam generator is in fluid connection with the tubular element to provide overheated steam to the continuous tow material
Implementation Method 2
At least one fluid conduit of the several fluid conduits comprises a temperature control unit including a temperature sensor and a temperature influencer
Implementation Method 3
Heat treatment with steam followed by cooling with air stabilizes the tow material in its rod shape
Data Source
AI summary
The forming apparatus comprises a feed path for continuously feeding a continuous tow material along a transport direction, a forming device connected to a downstream end of the feed path and adapted to form the continuous tow material into a continuous tubular rod. The forming device comprises a tubular element adapted to allow the continuous tow material to pass through the tubular element to form the continuous tubular rod and a steam generator adapted to generate overheated steam. The steam generator is in fluid connection with the tubular element to provide overheated steam to the continuous tow material. The forming device further comprises several fluid conduits to provide overheated steam from the steam generator to several injection sites arranged along a length of the tubular element, wherein at least one fluid conduit of the several fluid conduits comprises a temperature control unit including a temperature sensor and a temperature influencer.