Counter-Rotating Worm Melt Pump for High-Pressure Processing
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Solution Overview
Problem
Existing melt pumps, such as gear pumps and single worm pumps, face challenges including high manufacturing costs, pulsation at low rotational speeds, incomplete melt transfer, and increased energy consumption due to high rotational speeds, leading to friction and heat generation, which complicates the pressure boosting process and results in inefficient synthetic material processing.
Innovation Solution
A melt pump design with adjustable worm gaps between conveyors, allowing for optimal adaptation to different synthetic materials, featuring a compact structure with counter-rotating worm conveyors and a gear system that minimizes reflux and maximizes pressure buildup, reducing the need for a separate pressure boosting unit and enabling efficient synthetic melt processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high rotational speeds are used in existing melt pumps, then pressure buildup is achieved, but energy consumption increases and friction heat generation complicates the process
Solution Approach 1:
The invention changes the operational parameters by using counter-rotating worm conveyors that move in opposite directions, allowing pressure buildup without requiring high rotational speeds. This parameter change eliminates the need for high-speed operation while achieving the same pressure results, thereby reducing energy consumption and avoiding excessive heat generation.
Solution Approach 2:
The system employs dynamically adjusted worm gaps between the counter-rotating conveyors that can be adapted to different material viscosities and processing requirements. This dynamic adjustment allows optimal pressure buildup at lower rotational speeds, reducing energy consumption while maintaining effective melt transfer.
2Stress or pressure
If high rotational speeds are used in existing melt pumps, then pressure buildup is achieved, but friction increases causing heat generation
Solution Approach 1:
By changing the operational parameter from high rotational speed to counter-rotation at lower speeds, the invention achieves pressure buildup without generating excessive friction heat. The counter-rotating mechanism creates efficient melt transfer through opposing forces, reducing harmful heat generation while maintaining effective processing.
3Adaptability or versatility
If adjustable worm gaps are implemented, then adaptation to different synthetic materials is improved, but device complexity increases
Solution Approach 1:
The invention implements adjustable worm gaps that can be dynamically modified to suit different synthetic materials and their viscosity characteristics. This dynamic adjustability provides adaptability to various materials while maintaining a relatively simple device structure through straightforward mechanical adjustment mechanisms.
4Productivity
If counter-rotating worm conveyors are used, then pressure buildup efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The invention segments the pump into two independent counter-rotating worm conveyor units, each capable of being manufactured separately using standard worm pump technology. This segmentation allows for easier manufacturing of individual components while achieving superior pressure buildup efficiency through their coordinated counter-rotation operation.
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 design achieves efficient pressure buildup and reduced energy consumption, minimizing equipment costs and wear, while ensuring effective processing of synthetic materials with minimal thermal and mechanical damage, allowing for pressures up to 600 bar with a smaller, cost-effective setup.
Implementation Method 1
A melt pump design with adjustable worm gaps between conveyors, allowing for optimal adaptation to different synthetic materials, featuring a compact structure with counter-rotating worm conveyors and a gear system that minimizes reflux and maximizes pressure buildup
Implementation Method 2
featuring a compact structure with counter-rotating worm conveyors and a gear system
Data Source
AI summary
Melt pumps for pressing synthetic melt through a tool are disclosed. An example melt pump for building up pressure for pressing synthetic melt through a tool includes a compressor with two worm conveyors disposed in a housing, a transmission by means of which the worm conveyors are synchronously drivable, and a drive, where the transmission is disposed between the drive and the compressor. In the example melt pump, each worm conveyor in the transmission has an output shaft, and each worm conveyor is coupled to the corresponding output shaft by a coupling. In the example melt pump, the coupling comprises an output gear provided on the output shaft, and a drive gear provided on the worm conveyor and a coupling sleeve gripping the output gear and the drive gear, where the drive gear and the output gear have a different number of teeth.