Distributor Bar Geometry for Uniform Foam Deposition at High Speed
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Solution Overview
Problem
Existing systems for applying viscous foamable mixtures onto laminators at high speeds struggle to achieve uniformity, leading to non-uniformity, density gradients, and knit lines in the foamed layer due to the complexity of designing distributor bars that can handle high flow rates and reactive mixtures.
Innovation Solution
A distributor bar with a central inlet and equidistantly spaced outlets, designed using computational fluid dynamics simulations that account for non-Newtonian shear-thinning behavior, ensuring constant average velocity across outlets within a tolerance margin, and optimized geometry to reduce residence time and fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a distributor bar is designed for high laminator speeds with high flow rates, then productivity is improved, but manufacturing precision deteriorates due to non-uniform mixture distribution and knit lines
Solution Approach 1:
The distributor bar is designed with non-uniform outlet geometry where outer outlets have larger cross-sectional areas than central outlets. This local variation in outlet properties compensates for the non-uniform flow distribution caused by high laminator speeds, ensuring that each outlet delivers mixture at a velocity within the target range (2-4 m/s) to achieve uniform mixture layer deposition without knit lines
Solution Approach 2:
The invention changes the geometric parameters of the outlets, specifically the cross-sectional area, as a function of position along the distributor bar. By making the cross-sectional area increase from central to outer outlets, the system maintains constant average velocity across all outlets despite variations in flow rate, thereby achieving uniform deposition at high productivity
2Productivity
If the number of outlets is increased to cover wider laminator width, then productivity is improved, but device complexity increases making design and manufacturing more difficult
Solution Approach 1:
Instead of increasing the number of outlets, the invention changes the cross-sectional area parameter of outlets as a function of their position. This approach achieves wider laminator width coverage by optimizing the geometry of fewer outlets rather than adding more outlets, thereby reducing device complexity while maintaining productivity
Solution Approach 2:
The invention transitions from varying the number of outlets (discrete dimension) to varying the cross-sectional area parameter (continuous dimension). This dimensional shift allows for smoother optimization and reduces the complexity associated with designing and manufacturing multiple outlets with different configurations
3Reliability
If outlet velocity is increased to reduce residence time, then fouling is reduced, but manufacturing precision deteriorates due to non-uniform distribution
Solution Approach 1:
The distributor bar implements local quality by assigning different cross-sectional areas to outlets based on their position. This ensures that each outlet achieves the optimal velocity range (2-4 m/s) locally, preventing fouling while maintaining uniform mixture layer deposition. The outer outlets with larger areas compensate for their position to achieve velocity within the target range, matching central outlets
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 solution ensures a uniform expanded foam layer without gaps or knit lines, even at high laminator speeds, by accurately simulating and optimizing the distributor bar's geometry and outlet distribution, resulting in improved mechanical strength and density uniformity.
Implementation Method 1
designing and manufacturing a distributor bar having a central inlet for receiving a predefined viscous foamable liquid mixture... the number of outlets being spaced apart equidistantly over a predefined length... ensuring constant average velocity across outlets
Implementation Method 2
the mixture will leave each of the outlets with an average velocity which is constant for each of the outlets within a predefined tolerance margin
Data Source
AI summary
Method of designing and manufacturing a distributor bar for use in a production line comprising a mixing head for providing a viscous foamable liquid mixture, a laminator with a predefined speed of at least 20 m/min, the distributor bar having a central inlet fluidly connected to a number of outlets via a main channel. The method comprises: choosing (3001) a geometry for the distributor bar and defining a set of geometrical parameters; assigning (3002) values to said parameters; creating (3003) a virtual model; simulating (3005) flow in said model by performing a Computational Fluid Dynamics simulation (CFD), taking into account (3004) a non-Newtonian shear thinning model; e) evaluating the simulated flow; building (2007) a physical distributor bar. A distributor bar, a production line, and a computer program product.