Heated Roll Tension Device for Uniform Heat Distribution

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Solution Overview

Problem

Existing heated rolls face issues with uneven heat distribution on their exterior surface due to suboptimal contact between electric heating mats and the casing tube, leading to inconsistent temperature and quality problems in applications like hot-melt adhesive application.

Innovation Solution

A tension device is introduced inside the casing tube to press and pre-stress electric heating mats against the interior surface, ensuring uniform contact and heat transfer, accompanied by temperature sensors for regulation and overheating prevention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If electric heating mats are placed inside the casing tube without an inner tube, then the construction is simplified, but the heat distribution becomes very uneven

Engineering Contradiction:

Improveconstruction simplicityVSAvoidheat distribution uniformity

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

An inner tube made of thermally conductive metal is introduced as an intermediary component between the heating mats and the casing tube. This inner tube serves as a heat distribution mediator that receives heat from the heating mats and conducts it uniformly to the casing tube, resolving the contradiction between construction simplicity and heat distribution uniformity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heating mats are distributed around the annual clearance between the casing tube and inner tube, creating local heating zones that collectively provide uniform overall heating. This local quality approach ensures each area receives appropriate heat while maintaining construction simplicity.

Inventive Principle:

Principle #3Local quality

2Temperature

If multiple heating mats are distributed over the annual clearance, then temperature distribution becomes more even, but the device complexity increases

Engineering Contradiction:

Improvetemperature distribution uniformityVSAvoidnumber of heating mats and arrangement

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating system is segmented into multiple individual heating mats distributed around the annual clearance. Each mat is a separate, manageable unit that can be independently positioned and controlled, achieving uniform temperature distribution while keeping the overall device complexity manageable through modular segmentation.

Inventive Principle:

Principle #1Segmentation

3Object-generated harmful factors

If heating cartridges are used without thermic oil, then oil leakage protection is eliminated, but the heat distribution becomes very uneven

Engineering Contradiction:

Improveoil leakage riskVSAvoidheat distribution uniformity

Core Design Contradiction:

Object-generated harmful factorsVSTemperature

Solution Approach 1:

The inner tube acts as a mediator that enables direct contact between heating mats and the thermal mass of the casing tube structure, eliminating the need for thermic oil as a heat transfer medium while maintaining even heat distribution through the thermally conductive metal inner tube.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The thermic oil circulation system is replaced with a direct solid-to-solid heat conduction system using the inner tube and heating mats, eliminating the fluid mechanical system and its associated leakage risks while achieving better heat distribution control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution achieves a highly homogeneous temperature distribution across the casing tube, enhancing the quality of hot-melt adhesive application and other applications by maintaining consistent heat flow and preventing overheating.

Implementation Method 1

electrical heating mats into the annular clearance formed between the casing tube and the inner tube, which heat the casing tube from the inside to the desired temperature

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

arranging a tension device inside the casing tube which replaces the inner tube known from prior art and presses and/or pre-stresses the heating mats permanently against the interior surface of the casing tube

Methodology Applied

Scientific EffectMechanical pressure: Pressure Increase

Implementation Method 3

made from a thermally conductive metal... ensures a very homogenous, defined heat flow into the casing tube

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9693393B2Heated roll

Publication Date: 2017.06.27 ROBERT BURKE GMBH

AI summary

A heated roll with a circular cylindrical casing tube 1 made from thermally conductive metal, which is closed at its end faces with caps 2, 3. One or more electric heating mats 8 are arranged inside the casing tube 1. By at least one connection pin 5, which is arranged at one cap 2, connection cables 11 are guided for supplying the heating mats 8 with electric power. Annular brushing bodies 7 are fastened at the connection pin 5 and serve for the electric contacting of the connection cables 11. A tensioning device 9, 14, 15 is arranged inside the casing tube 1, which presses the heating mats 8 permanently against the interior surface of the casing tube 1.