Extruder Injector Conduit Cooling and Smooth Flow Design
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Solution Overview
Problem
The existing injection apparatus for fluid formulations into molten polymeric materials is prone to blockages, especially at low let-down-ratios, leading to significant downtime and production losses due to the need for disconnection and cleaning, which is exacerbated by temperature-related issues affecting the fluid formulations.
Innovation Solution
The apparatus incorporates a conduit with a cooling fluid passageway and a securement device that maintains a cooling fluid flow to prevent temperature rises and includes a design with smooth, non-screw-threaded cylindrical regions to reduce the risk of blockages, ensuring continuous and accurate injection of fluid formulations into molten polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the injection apparatus operates at high pressure to deliver liquid formulation into molten polymer, then the injection accuracy and delivery rate are improved, but the risk of blockage in the conduit and injector increases
Solution Approach 1:
The patent applies parameter changes by introducing cooling fluid to reduce the temperature of the liquid formulation in the conduit. This temperature reduction changes the physical state parameters of the formulation, preventing it from thickening or solidifying during high-pressure injection, thereby maintaining delivery rate while preventing blockages
Solution Approach 2:
The cooling fluid acts as an intermediary substance that transfers heat from the liquid formulation in the conduit. By introducing this intermediary cooling medium, the system can maintain high injection pressure without the formulation reaching temperatures that would cause thickening or blockage
2Strength
If the conduit is designed with screw-threaded regions for securement, then the attachment strength to the extruder is improved, but the risk of blockage increases due to threading surfaces
Solution Approach 1:
The patent segments the conduit design into distinct functional regions: smooth cylindrical sections for fluid flow and separate screw-threaded sections for attachment. This segmentation allows the conduit to have strong attachment capability where needed while maintaining smooth surfaces in the fluid passage to prevent blockages
Solution Approach 2:
The patent applies local quality by providing different surface characteristics in different locations of the conduit. The fluid passage sections have smooth surfaces to prevent blockage, while the attachment sections have screw-threaded surfaces for securement. This localized differentiation of surface properties resolves the contradiction between attachment strength and blockage prevention
3Ease of operation
If the liquid formulation is heated to match the molten polymer temperature, then the viscosity matching and injection flow are improved, but the formulation may thicken or solidify in the conduit
Solution Approach 1:
The patent uses cooling fluid to change the temperature parameter of the liquid formulation in the conduit, reducing it below the molten polymer temperature. This parameter change prevents the formulation from thickening or solidifying during transport, while the formulation can be heated at the injection point if needed for proper flow matching
4Manufacturing precision
If the injection system is designed with tight sealing and high pressure capability, then the injection precision is improved, but the downtime for cleaning increases when blockages occur
Solution Approach 1:
By introducing cooling fluid to maintain the liquid formulation in a lower temperature state, the patent prevents thickening and blockage formation. This parameter change allows the high-precision injection system to operate continuously without frequent cleaning interruptions, maintaining both injection precision and productivity
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 effectively reduces the risk of blockages and maintains accurate fluid delivery, minimizing downtime and ensuring consistent production by maintaining the fluid formulation's integrity and preventing temperature-induced thickening or solidification within the injection system.
Implementation Method 1
a conduit (17) having a cooling fluid passageway (50) arranged to contain cooling fluid, wherein said cooling fluid passageway (50) is arranged to maintain a cooling fluid flow therethrough
Data Source
Figure 1~2
Figure 3
Figure 4a~4b
AI summary
Polymeric Materials An injector (14) for injecting liquid formulation into molten polymer includes a conduit (117) having regions (44, 46) which are secured within a wall of an extruder (19). Conduit (117) includes an annular collar (120) having an upwardly facing annular surface (122) which is arranged to bear against part of a sleeve nut (124). Conduit (117) is arranged within a port (125) which includes a screw-threaded wall (126). The sleeve nut (124) includes a cylindrical body (146) having an inwardly facing cylindrical wall which is arranged to define a cylindrical air gap (148) between itself and an outer wall (147) of conduit (117). Region (150) of the sleeve nut is screw-threadedly engaged in wall (126) of the extruder. In use, cool compressed air is introduced into the assembly in the direction of arrow (170) and it flows through the assembly to cool it.