Cross-Channel Packing Production Without Sheet Coiling
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Solution Overview
Problem
The existing methods for producing cross-channel corrugated sheet packings made of expanded metal sheets are inefficient and costly due to transportation issues and misalignment during processing, leading to deformation and increased material expenses.
Innovation Solution
A plant and process that includes a stretching machine, calibration machine, sheet storage unit, forming machine, and stacking machine to produce structured cross-channel packing elements with adjacent layers of expanded metal sheets, allowing for direct transportation and forming without coiling, which maintains the metal sheet's direction and reduces deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If expanded metal sheets are coiled under tension onto sleeves for transport and processing, then transportation is enabled, but the sheets cannot be coiled exactly edge-on-edge causing misalignment, tension, and deformation
Solution Approach 1:
The process is segmented into distinct stages: production, direct transport without coiling, and processing. By eliminating the coiling intermediate step, the patent avoids the alignment problems inherent in coiling while maintaining transportation capability through direct handling methods.
Solution Approach 2:
The patent performs preliminary actions at the production stage by preparing sheets for direct transport in their flat state before processing. This preliminary preparation eliminates the need for subsequent coiling and uncoiling operations that cause misalignment and deformation.
2Ease of operation
If expanded metal sheets are transported and processed in conventional manner with coiling, then transportation is achieved, but processing time increases and material costs rise due to deformation
Solution Approach 1:
The patent establishes a continuous production process where expanded metal sheets flow directly from the stretching machine through the forming machine without interruption for coiling and uncoiling. This continuous action eliminates wasted time and maintains production efficiency.
Solution Approach 2:
The patent skips the conventional coiling and uncoiling steps entirely, rushing through the production process with direct transport and processing. This eliminates the time-consuming intermediate operations that reduce productivity.
3Adaptability or versatility
If metal sheets are stretched and formed in separate operations with coiling in between, then processing flexibility is maintained, but misalignment occurs leading to deformation and increased material expenses
Solution Approach 1:
The patent merges the transport function with the production line by integrating direct sheet transfer from stretching to forming operations. This consolidation eliminates the separate coiling operation that causes misalignment while maintaining the necessary processing flexibility.
Solution Approach 2:
The patent introduces a direct transport mechanism as an intermediary between stretching and forming operations, replacing the problematic coiling sleeve. This intermediary enables smooth sheet transfer without the alignment issues caused by conventional coiling methods.
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 process enables the efficient and cost-effective production of structured cross-channel packing elements with improved flow resistance and reduced pressure loss, enhancing mass transfer and heat exchange efficiency between fluid phases.
Implementation Method 1
a) a stretching machine for cutting and stretching a metal sheet to an expanded metal sheet
Implementation Method 2
e) a forming machine for forming the expanded metal sheet produced in the stretching machine
Implementation Method 3
at least two of the at least two layers are arranged in the longitudinal direction of the packing element parallel and in touching contact with each other so that an open space extending from one end to the opposite end of the at least two layers is provided between them so that at least one of the heavy and the light fluid phase may flow through it
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The present invention relates to a plant for producing a structured cross-channel packing element for a column for mass transfer and/or heat exchange between a heavy and a light fluid phase, wherein the structured cross-channel packing element comprises at least two adjacent layers made of expanded metal sheets each comprising openings, which are surrounded and separated from each other by separating elements, and comprising periodic deformations, wherein at least two of the at least two layers are arranged in the longitudinal direction of the packing element parallel and in touching contact with each other so that an open space extending from one end to the opposite end of the at least two layers is provided between them so that at least one of the heavy and the light fluid phase may flow through it, wherein the plant comprises: a) a stretching machine for cutting and stretching a metal sheet to an expanded metal sheet, b) optionally, a calibration machine for rolling the expanded metal sheet produced in the stretching machine (a) to a desired thickness, c) a sheet storage unit, d) a forming machine for forming the expanded metal sheet produced in the stretching machine and optionally rolled in the optional calibration machine to an expanded metal sheet comprising periodic deformations and e) a stacking machine for stacking expanded metal sheets comprising periodic deformations to a structured cross-channel packing element, wherein the sheet storage unit is embodied so that it directly receives the expanded metal sheet produced in the stretching machine and optionally rolled in the optional calibration machine and releases the expanded metal sheet directly to the forming machine.