Cooling Roll Non-Perpendicular Flow Deflection
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Solution Overview
Problem
Conventional chill rolls used in the production of plastic films often result in transverse markings on cast films, particularly when slow-running, which cannot be effectively explained or prevented by existing technologies.
Innovation Solution
The chill roll design incorporates non-perpendicular coolant flow direction changes, using deflection devices such as cone tips and angled riser pipes to minimize turbulence, and employs a countercurrent cooling principle with degressive cooling channels to improve coolant flow and reduce vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional chill rolls with perpendicular coolant flow transitions are used, then the cooling function is provided, but transverse markings appear on cast films
Solution Approach 1:
The patent changes the flow direction angle parameter from the conventional 90 degrees to angles between 45-60 degrees or 120-135 degrees. This parameter modification reduces turbulence intensity and prevents the formation of transverse markings on the cast film surface while maintaining effective cooling function.
Solution Approach 2:
The patent introduces curved transition sections instead of sharp perpendicular angles in the coolant flow paths. The curved geometry of the transition sections between coolant inlets/outlets and the cooling channels reduces flow separation and turbulence, thereby eliminating the harmful transverse markings on the film.
2Loss of energy
If slow-running cooling rollers are used, then energy consumption is reduced, but transverse markings become more pronounced
Solution Approach 1:
By changing the flow direction angles to 45-60 degrees or 120-135 degrees, the patent enables slow roller speeds to be used without generating transverse markings. The optimized angle parameters reduce turbulence at low rotational speeds, allowing energy-efficient operation while maintaining film quality.
3Device complexity
If right-angle changes in coolant flow direction are provided, then device complexity is minimized, but turbulence is generated causing vibrations
Solution Approach 1:
The patent replaces sharp right-angle transitions with curved transition sections in the coolant flow paths. These curved sections, with radii specifically designed relative to the channel dimensions, reduce flow separation and turbulence, thereby minimizing vibrations while adding minimal geometric complexity.
Solution Approach 2:
The patent optimizes the dynamic characteristics of coolant flow by using angled transitions (45-60 degrees or 120-135 degrees) that reduce flow separation and turbulence intensity. This dynamic optimization reduces vibrations transmitted to the roller and cast film without significantly increasing structural complexity.
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 design significantly improves the quality of cast films by eliminating or suppressing transverse markings, resulting in better film properties and a more uniform cooling effect.
Implementation Method 1
a cooling medium can be supplied to at least one of the cooling channels (21) and/or to the flow chamber (11) via a supply line (25), wherein at least one change in the flow direction of the cooling medium is generated by a non-perpendicular arrangement of corresponding pipe or channel sections
Implementation Method 2
The coolant is supplied to one end of the cooling roller and discharged to the opposite end. This is usually done via radial riser pipes, through which the coolant is fed radially into the flow chamber located below the roller shell
Data Source
Figure 1~2
Figure 3
Figure 4~4b
AI summary
An improved cooling roller is characterized, among other things, by the fact that various flow deflection devices (41, 41'; 141, 141') are provided between different pipe sections of the coolant flow pipe system (KD) passing through the cooling roller, which are designed in such a way that the coolant flow undergoes a non-perpendicular change in flow direction.