Heavy Load Vortex Trough for Plastic Granule Crystallization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing swirling trough devices are limited by design and can only handle relatively small product throughput rates due to high mass forces transverse to the vertical and longitudinal directions, leading to inefficiencies in crystallization processes for plastic granules like PLA and PET.
Innovation Solution
A heavy-duty swirling trough device with a vibrating trough and supports designed to manage high mass forces, featuring a trough base inclined in the longitudinal direction and vibration exciters positioned to generate a transverse vibration component, allowing for a helical movement of granules and maintaining product quality at higher throughput rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional swirling trough devices are used, then crystallization treatment can be performed, but product throughput rate is limited due to high mass forces
Solution Approach 1:
The device divides the single large trough into multiple smaller troughs arranged side by side. Each trough handles a portion of the total product flow, reducing the mass forces in each individual trough while maintaining high overall throughput capacity. This segmentation allows the device to process 3-10 tons of product without quality loss.
Solution Approach 2:
The invention transitions from a single wide trough to multiple narrower troughs arranged in parallel. This dimensional reorganization distributes the load across multiple channels, effectively reducing the transverse mass forces in each trough while preserving the total processing capacity through the parallel arrangement.
2Manufacturing precision
If vibration excitation with transverse component is applied, then helical movement and homogeneous temperature profile are achieved, but device complexity increases
Solution Approach 1:
The vibration excitation system is segmented across multiple troughs, with each trough receiving vibration from dedicated exciters. This distributes the complexity across modular units rather than requiring a single complex excitation system, making the overall device more manageable and maintainable.
Solution Approach 2:
The vibration exciters serve multiple functions: they generate the transverse component for helical movement, control temperature distribution, and prevent granule adhesion. This multi-functionality reduces the need for separate systems, offsetting the complexity with operational efficiency.
3Productivity
If multiple vibration exciters are used, then high mass forces are managed, but device complexity increases
Solution Approach 1:
Each trough is equipped with its own vibration exciters, creating modular independent units. This segmentation allows each exciter to handle only the mass forces in its specific trough, reducing the burden on individual exciters while achieving high overall throughput through parallel operation of multiple troughs.
Solution Approach 2:
The vibration exciters are configured to provide dynamic control over the granule flow in each trough. By adjusting vibration parameters independently in each trough, the system optimizes throughput while managing mass forces, achieving high productivity without requiring excessive exciters.
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
Enables the treatment of product quantities up to 3 to 10 tons without quality loss, achieving accelerations of 30 to 60 kgm/s2 and maintaining a homogeneous temperature profile, thus enhancing the crystallization process efficiency.
Implementation Method 1
at least two vibration exciters for generating a vibration excitation which has a transverse component perpendicular to a plane which is spanned by the longitudinal direction of the vibrating trough and the vertical direction. This special type of vibration excitation causes a helical movement of the granules in the longitudinal direction of the vibrating trough
Implementation Method 2
This results in an uninterrupted, continuous granule flow with high interaction of the granule particles with one another, such that these can exchange process heat with one another
Implementation Method 3
the length of the vibrating trough in the longitudinal direction is greater than the maximum height and width of a trough cross-section perpendicular to the longitudinal direction
Data Source
AI summary
A heavy load vortex internal apparatus is provided having a vibration channel for receiving plastic granular material. The vibration channel has a channel floor and two side walls opposite each other, where the length of the vibration channel is greater in the longitudinal direction than the maximum height and width of a channel cross section perpendicular to the longitudinal direction. At least two vibration generators are provided for generating a vibration excitation having a transverse component perpendicular to a vertical plane in the longitudinal direction. At least two channel carriers are spaced apart from each other in the longitudinal direction, each supporting the channel floor and the side walls from the outside and bridging the vibration channel opposite the channel floor. One of the vibration generators in each case is fastened to at least two of the channel carriers. Also provided is a method for crystallization of plastic granular material.