Hopper Process Fluid Diffuser for Uniform Plastic Conditioning
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Solution Overview
Problem
Existing dehumidifying and drying hoppers for plastics suffer from non-uniform thermal conditioning, preferential flow channels, and constructional defects leading to inconsistent dehumidification and thermal gradients, which compromise the quality of the final product.
Innovation Solution
A hopper design featuring a cylindrical main portion with a tapered lower portion and a process fluid diffusing system using loose, granular material to create multiple diffusion channels, preventing preferential passages and ensuring uniform fluid distribution, while the diffuser configuration with double conicity and additional features like thermoinsulating material and annular supplying chambers optimize thermal transfer and reduce load losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a drilled conical hollow insert is used as process fluid diffusing device, then mass flow type granule descent is achieved, but thermal gradient in granules increases and dehumidification uniformity deteriorates
Solution Approach 1:
The diffusing device is segmented into multiple independent drilled walls arranged concentrically, with each wall providing separate diffusion channels. This segmentation allows process fluid to be distributed through multiple pathways simultaneously, preventing thermal concentration in a single channel while maintaining uniform granule descent.
Solution Approach 2:
The invention transitions from a single conical diffusing structure to multiple concentric cylindrical drilled walls, adding a radial dimension to the diffusion system. This multi-dimensional arrangement creates distributed diffusion channels that reduce thermal gradients by spreading heat transfer across multiple spatial dimensions.
2Productivity
If process fluid flowrate is increased to improve dehumidification, then dehumidification efficiency improves, but thermal gradient increases and uniformity deteriorates
Solution Approach 1:
The process fluid flow is segmented into multiple independent diffusion channels through the concentric drilled walls. This allows the total flowrate to be distributed across many smaller channels, maintaining high overall dehumidification efficiency while preventing thermal gradients that would occur in single-channel systems.
Solution Approach 2:
Each drilled wall creates localized diffusion zones with controlled flow characteristics. The local quality of fluid distribution is optimized by having multiple walls at different radial positions, each contributing to uniform thermal conditioning of granules in different regions of the hopper.
3Stability of the object's composition
If tapered lower portion is added to hopper, then mass flow type descent is achieved, but constructional complexity increases
Solution Approach 1:
The tapered lower portion is merged with the diffusing device structure, combining the flow-control function of the taper with the fluid-distribution function of the drilled walls. This integration achieves mass flow descent and uniform thermal conditioning simultaneously without adding separate complex components.
Solution Approach 2:
The tapered lower portion serves multiple functions: it maintains mass flow type granule descent, provides structural support for the diffusing device, and facilitates uniform distribution of both granules and process fluid. This multi-functionality reduces overall system complexity despite the added geometric feature.
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 ensures uniform thermal conditioning and dehumidification, reduces thermal gradients, and stabilizes the flow of process fluid, resulting in improved product quality by maintaining consistent temperature and humidity levels across the hopper.
Implementation Method 1
the process fluid delivered to the at least one dehumidifying and/or drying hopper pass through the mass of granules to be conditioned thermally, removes the humidity contained therein
Implementation Method 2
Dehumidifying and/or drying the plastics, i.e. removing water contained in hygroscopic granules
Data Source
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AI summary
A hopper (1) for thermally conditioning by a process fluid plastics in granular and/or microgranular and/or powder and/or flake or similar form, comprises: a containing body (2) for containing said plastics to be thermally conditioned, and process fluid diffusing means (11), positioned inside the containing body (2), and comprising drilled wall means (12) in flowing communication with the containing body (2) to diffuse the process fluid inside the containing body (2); in which the process fluid diffusing means (11) comprises process fluid supplying chamber means (13) bounded externally by the drilled wall means (12); wherein the process fluid diffusing means (11) comprises loose material (14) for filling, at least partially, the supplying chamber means (13) so as to form in the supplying chamber means (13) a plurality of passages for the process fluid so as to homogenize and stabilize a flow of the process fluid exiting the supplying chamber means (13).