Continuous Electron Beam Cross-Linking of Flexible Plastic Hose
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Solution Overview
Problem
Existing electron beam networking processes for flexible plastic hoses are complex and inefficient, often resulting in incomplete networking of inner windings due to the need for multiple turns and cooling periods to prevent overheating.
Innovation Solution
A continuous electron beam networking process where a flexible plastic hose is continuously transported past an electron beam source at a constant speed, allowing for complete networking of the hose cross-section without the need for multiple turns or cooling periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plastic hose is fed in separate bundles to the electron beam source, then the cross-linking process can be performed, but the inner windings of the hose bundle remain incompletely cross-linked and the process becomes complex with multiple turns and cooling periods required
Solution Approach 1:
The invention segments the hose into individual units by feeding them one at a time through the electron beam source rather than as bundled groups. This segmentation allows complete electron beam penetration of each hose cross-section, ensuring uniform cross-linking throughout the entire hose wall thickness without the shielding problems that occur in bundled configurations.
Solution Approach 2:
The invention changes the spatial arrangement from horizontal bundle feeding to vertical individual hose feeding through the electron beam source. This dimensional change allows the electron beams to penetrate the hose wall more effectively and ensures complete cross-linking of all windings without requiring multiple turns and cooling periods.
2Reliability
If the hose is irradiated multiple times to ensure complete cross-linking, then cross-linking quality improves, but the process time increases and overheating occurs
Solution Approach 1:
The invention performs preliminary action by precisely controlling the electron beam parameters and hose feed rate to achieve complete cross-linking in a single pass. The hose is fed at an optimized speed that allows sufficient electron beam penetration and energy deposition to cross-link the entire hose wall thickness without requiring subsequent re-irradiation cycles.
Solution Approach 2:
The invention changes critical parameters including electron beam energy level, hose feed rate, and beam current density to optimize the cross-linking process. By adjusting these parameters, the system achieves complete cross-linking in a single continuous pass, eliminating the need for multiple irradiation cycles and cooling periods while preventing overheating.
3Productivity
If the hose is fed continuously at high speed, then productivity increases, but complete cross-linking of the hose cross-section becomes difficult to achieve
Solution Approach 1:
The invention introduces dynamic control by continuously adjusting the hose feed rate based on real-time monitoring of cross-linking quality. The system maintains optimal processing speed by dynamically balancing the feed rate with electron beam parameters, ensuring complete and uniform cross-linking throughout the hose wall while maintaining high productivity through continuous 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
This process ensures complete networking of the hose, avoiding the chronic weak point of incomplete inner winding networking, while also being more efficient and safer in terms of occupational safety and energy usage.
Implementation Method 1
the crosslinkable tube layer is bombarded with electrons, generating activation energy that leads to crosslinking of the polymer chains
Implementation Method 2
generating activation energy that leads to crosslinking of the polymer chains
Data Source
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AI summary
The invention relates to a method for electron beam cross-linking of a flexible plastic hose (1) by means of at least one electron beam source (2), wherein the plastic hose (1) expediently comprises at least one hose layer (7) of a cross-linkable plastic material, preferably polyethylene. The flexible plastic hose (1) is fed in a continuous manner with a preferably constant transport speed (v) to a cross-linking device (4) comprising the electron beam source (2). A cross-linking of the plastic hose (1) is then carried out by electron irradiation (E) of the plastic hose (1) that is continuously passed along the electron beam source (2).