Full-nitrogen circulation, heating and vulcanization system, and vulcanization method
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Solution Overview
Problem
The co-vulcanization process of steam and nitrogen in the tire industry faces issues such as environmental pollution, high energy consumption, uneven temperature distribution, and pressure fluctuations, which affect vulcanization quality and do not align with low-carbon and environmentally-friendly requirements.
Innovation Solution
An annular seat cylinder head and a gas heater utilizing electromagnetic induction heating technology are introduced to ensure uniform temperature and stable pressure during nitrogen circulation, along with a comprehensive vulcanization system that includes a circulation pipeline, buffer tanks, and a nitrogen production system to manage pressure and temperature effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam is used for heating in co-vulcanization, then heat source is provided, but environmental pollution and high energy consumption occur
Solution Approach 1:
The patent extracts and removes the steam heating component from the vulcanization system, replacing it with direct nitrogen circulation heating. This eliminates the harmful byproducts of steam generation (sulfur dioxide, carbon monoxide) while maintaining the necessary temperature for vulcanization through electric heating elements that heat nitrogen directly.
Solution Approach 2:
The patent replaces the mechanical steam generation system with an electric heating system that directly heats nitrogen gas. This substitution eliminates the need for boilers and steam circulation infrastructure, reducing environmental pollution and energy consumption while achieving the same thermal effect for vulcanization.
2Temperature
If steam is used for heating, then heat source is provided, but energy consumption is high
Solution Approach 1:
The patent removes the steam generation and circulation system, which is energy-intensive, and replaces it with direct electric heating of nitrogen. This extraction of the steam system eliminates the energy losses associated with water heating, steam generation, and condensation, significantly reducing overall energy consumption.
Solution Approach 2:
The patent implements continuous nitrogen circulation with continuous electric heating, maintaining constant temperature without the intermittent heating cycles required by steam systems. This continuous action ensures efficient energy utilization and consistent vulcanization temperature, reducing total energy consumption.
3Temperature
If steam vulcanization is used, then heating is achieved, but temperature distribution is uneven
Solution Approach 1:
The patent employs multiple electric heating elements positioned at different locations within the vulcanization chamber to heat nitrogen locally at specific zones. This localized heating approach ensures uniform temperature distribution throughout the chamber, preventing the uneven heating problems associated with steam condensation on capsule surfaces.
Solution Approach 2:
Replacing the steam heating system with electric heating elements provides more precise and uniform heat distribution. The electric heaters can be strategically positioned and controlled to ensure even temperature across all areas of the vulcanization chamber, improving manufacturing precision and product quality.
4Temperature
If nitrogen circulation is implemented, then uniform temperature can be achieved, but requirements on spray inlet and nitrogen outlet are raised
Solution Approach 1:
The patent divides the cylinder head into functionally distinct segments: a spray inlet section with optimized nozzle arrangements for uniform nitrogen distribution, and a separate outlet section for nitrogen extraction. This segmentation allows each part to be optimized independently, achieving uniform temperature circulation while managing structural requirements through modular design.
5Stress or pressure
If co-vulcanization with steam and nitrogen is used, then pressure control is improved, but condensed water causes uneven vulcanization
Solution Approach 1:
The patent completely removes the steam component from the co-vulcanization process, using nitrogen alone for both pressure control and heating. This extraction eliminates the source of condensed water formation, preventing the uneven vulcanization that occurs when steam condenses on the capsule and tire surfaces during the process.
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 achieves energy-efficient, environmentally-friendly vulcanization with uniform temperature and stable pressure, improving tire quality and reducing energy waste.
Implementation Method 1
a gas heater utilizing electromagnetic induction heating technology are introduced to ensure uniform temperature and stable pressure during nitrogen circulation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Provided are an all-nitrogen circulating heating and vulcanization system and vulcanization method. The system includes a circulation pipeline (7). A circulation pump (1), a gas heater (4), a nitrogen heating uniformity apparatus (6), an annular seat cylinder head, a capsule (31), a circulation buffer tank (15), and a filter (16) are disposed on the circulation pipeline (7) sequentially. The capsule (31) is disposed on the annular seat cylinder head. The circulation buffer tank (15) is connected to a nitrogen supplement pipeline (33). A nitrogen production system (22), a low-pressure nitrogen buffer tank (23), a booster pump (24), a high-pressure nitrogen buffer tank (25), a pressure reducing valve (26), and a nitrogen supplement one-way valve (27) are disposed on the nitrogen supplement pipeline (33) sequentially. A recovery pipeline (20) is disposed between the capsule (31) and the low-pressure nitrogen buffer tank (23). A vacuum pump (29) and a first recovery valve (28) are disposed on the recovery pipeline (20). A second recovery valve (30) is connected in parallel to a head end of the vacuum pump (29) and a tail end of the vacuum pump (29). A cooling pipeline (32) is connected in parallel on the circulation pipeline (7). A first cooling valve (17), a second cooling valve (18), and a cooling apparatus (19) are disposed on the cooling pipeline (32).