Heat Form Coiling Device for Plastic Tubing
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Solution Overview
Problem
Existing methods for forming plastic tubing into coils are inefficient, labor-intensive, and costly, particularly when using ultra-high molecular weight polyethylene mandrels and ovens.
Innovation Solution
A coiling system that continuously forms coiled plastic tubing using a rotating main tube shaft with a variable-speed motor, an oblique tube guide, a heat source to soften the tubing, and a cool-air source to set the coil, followed by cutting into desired lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic tubing is coiled using a traditional mandrel and oven method, then the tubing can be formed into a coil, but the process becomes labor-intensive and expensive
Solution Approach 1:
The patent replaces the traditional mechanical mandrel system with a thermal field-based coiling method. A heat source softens the tubing material, allowing it to conform to a coiling surface without requiring complex mechanical mandrels or manual wrapping operations. This substitution of mechanical systems with thermal processing reduces labor intensity and simplifies the manufacturing process.
Solution Approach 2:
The patent utilizes temperature as a critical parameter to change the physical state of the plastic tubing. By heating the tubing to its softening point, the material transitions from a rigid state to a pliable state, enabling it to be formed into coils. This parameter change allows for automated continuous coiling without manual intervention, thereby improving productivity while maintaining ease of manufacture.
2Manufacturing precision
If plastic tubing is coiled using a mandrel and oven, then coils can be produced, but the method is inefficient and costly
Solution Approach 1:
The patent eliminates the need for large oven chambers and complex mandrel positioning mechanisms by using a localized heat source that travels with the tubing. This thermal field approach maintains precise coil formation through controlled material softening while enabling continuous high-speed production, thereby resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The patent implements a continuous coiling process where tubing is constantly fed, heated, and formed into coils without interruption. The heat source moves continuously along with the tubing, maintaining the material in a softened state throughout the coiling operation. This continuous action eliminates the batch processing nature of traditional oven methods, significantly improving productivity while maintaining consistent coil quality.
3Ease of manufacture
If traditional coiling methods are used, then tubing can be formed into coils, but the process is very labor-intensive
Solution Approach 1:
The patent replaces manual wrapping and positioning operations with an automated thermal processing system. The heat source automatically softens the tubing as it passes through the coiling zone, and the material naturally conforms to the coiling surface due to its softened state. This eliminates the need for operators to manually manipulate the tubing, dramatically reducing labor intensity while keeping the manufacturing process simple and easy to operate.
Solution Approach 2:
The softened tubing material essentially forms the coils itself through its own plasticity when heated. The material flows and conforms to the coiling surface under its own weight and the guiding action of the system, without requiring external mechanical force or manual intervention. This self-forming characteristic reduces labor requirements to minimal monitoring and material feeding, greatly improving ease of 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
The system provides a more economical and efficient method for producing coiled plastic tubing, reducing labor and costs while ensuring precise control over the coiling process.
Implementation Method 1
a heat source is directed toward the coiled tubing, softening it as it traverses
Implementation Method 2
a cool-air source, which is directed toward the coiled tubing and sets it into its coiled form
Data Source
AI summary
A method and apparatus for continuously producing preselected lengths of coiled tubing are disclosed. According to the method, plastic tubing is continuously wound onto a rotating main tube shaft (24). Downstream from the point where the tubing begins to wind about the shaft, a heat source (46) is directed toward the coiled tubing, softening it as it traverses thereby. Further downstream, a cool-air source (48) directed at the softened tubing sets the tubing into its coiled form. Subsequently, the coiled tubing is cut into preselected lengths by a cutter (50) downstream from the cool-air source.