Intermeshing Kneader Rotor Segmentation for Cooling and Pressure Control

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Solution Overview

Problem

Conventional kneaders face issues with insufficient cooling during the kneading process, particularly for materials with low thermal conductivity like rubber, leading to temperature control challenges and the need for multiple passes, and rely on unreliable pneumatic systems for batch processing.

Innovation Solution

The design incorporates intermeshing rotors with a hydraulic ram for controlled pressure and enhanced cooling, allowing for single-pass mixing and improved dispersion by using a two-piece rotor with a spiral water passage and wider blades, along with a hydraulic locking mechanism to ensure consistent batch processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional kneaders use small mixing volume to provide sufficient cooling, then temperature control is improved, but productivity decreases

Engineering Contradiction:

Improvekneaded material temperature controlVSAvoidmixing capacity

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The rotor is divided into multiple segments including a rotor shaft, multiple wings, and nogs that can be independently positioned. This segmentation allows optimization of cooling surface area without compromising mixing volume, as each segment can be designed to maximize heat dissipation while maintaining overall mixer capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces a new dimension for cooling by adding nogs that extend axially from the wings, creating additional cooling surfaces in the axial direction. This multi-dimensional approach to cooling surface creation allows sufficient heat dissipation while maintaining large mixing volume for high productivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If conventional kneaders use pneumatic pressure for batch processing, then operation is simplified, but reliability and consistency deteriorate

Engineering Contradiction:

Improvebatch processing operationVSAvoidram position control

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The invention replaces the pneumatic system with a hydraulic system. The hydraulic ram provides controlled, consistent, and reliable pressure application for batch processing. Hydraulic systems offer better position control and reliability compared to pneumatic systems while maintaining ease of operation through fluid power actuation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If conventional kneaders use long, high, and narrow blades, then mixing action is provided, but cooling efficiency is insufficient

Engineering Contradiction:

Improvemixing actionVSAvoidcooling efficiency

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The rotor blade is segmented into multiple wings (typically 3-5) arranged around the rotor shaft, with each wing providing both mixing action and cooling surface. This segmentation increases the total cooling surface area compared to a single long blade, while maintaining effective mixing through the distributed wing configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wings are designed with curved surfaces that wrap around the rotor shaft, maximizing the cooling surface area in contact with the kneaded material. The curved geometry provides both effective mixing action through material displacement and enhanced cooling efficiency through increased surface area.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Adaptability or versatility

If conventional kneaders allow differential rotor speeds, then mixing flexibility is improved, but temperature control worsens

Engineering Contradiction:

Improvemixing flexibilityVSAvoidinternal temperature control

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The rotor is segmented into multiple wings and nogs that can be independently positioned at different angles. This allows optimization of mixing patterns for different materials while maintaining synchronized rotation for consistent temperature control. The segmented design provides mixing flexibility without requiring differential speeds.

Inventive Principle:

Principle #1Segmentation

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 enables efficient temperature control and reduced mixing time, allowing for the addition of curing agents in the primary mixing cycle without pre-cooling, while improving batch consistency and productivity through controlled hydraulic pressure and increased cooling efficiency.

Implementation Method 1

a movable hydraulically driven ram applies a controlled pressure on the batch during mixing

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Implementation Method 2

enhanced cooling... using a two-piece rotor with a spiral water passage

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 3

two intermeshing mixing rotors within the mixing chamber... co-rotating opposite directions

Methodology Applied

Scientific EffectMechanical mixing: Stirring

Data Source

PatentEP1937453B8Intermeshing kneader

Publication Date: 2014.08.13 HANADA SHIRO

AI summary

A closed kneader mixing machine (10) including a tilting mixing chamber (20) and a pair of counter rotating intermeshing rotors (40) rotatably mounted within the tilting mixing chamber. The courter-rotating intermeshing rotors may be synchronous rotors.