Monomode Applicator for Controlled Microwave Rubber Cross-Linking
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Solution Overview
Problem
Existing microwave crosslinking devices suffer from uncontrolled microwave propagation, leading to inefficient energy absorption by the workpiece, potential damage to surrounding components, and undesirable crosstalk effects, with only approximately 20% of microwave energy being effectively utilized.
Innovation Solution
The use of monomode applicators, such as waveguides, striplines, or cavity resonators, which are designed to propagate microwaves in a controlled manner, allowing precise positioning of the workpiece within the microwave field for maximum energy absorption and selective heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional microwave sources with coupling slots are used to heat rubber profiles, then the rubber profile can be vulcanized, but the microwave energy propagation is uncontrolled and only approximately 20% of the microwave energy is effectively absorbed by the profile
Solution Approach 1:
The device divides the treatment space into multiple independently controllable microwave zones along the transport direction. Each zone has its own microwave source and can be controlled separately, allowing precise energy delivery to different segments of the workpiece at different times, thereby improving overall energy utilization efficiency.
Solution Approach 2:
The system pre-calculates and pre-positions microwave sources and workpiece transport to ensure optimal alignment before microwave irradiation begins. The control unit coordinates the timing and positioning so that microwave energy is applied at the most effective moment and location, maximizing energy absorption before the workpiece moves out of the irradiation zone.
2Power
If multiple microwave sources are located in close proximity to each other, then higher power output is achieved, but detrimental crosstalk effects occur between the microwave sources
Solution Approach 1:
The device divides the treatment space into multiple independently controllable microwave zones along the transport direction. Each zone has its own microwave source and can be controlled separately, allowing precise energy delivery to different segments of the workpiece at different times, thereby improving overall energy utilization efficiency.
Solution Approach 2:
The system activates microwave sources in a sequential, periodic manner rather than simultaneously. Each microwave source operates in alternating intervals as the workpiece passes through its zone, ensuring that when one source is active, others are inactive or in low-power standby mode, thus eliminating crosstalk while maintaining continuous high-power treatment.
3Object-affected harmful factors
If microwaves are extensively absorbed before exiting the device to prevent damage to the surrounding area, then safety is improved, but the device complexity and energy loss increase
Solution Approach 1:
The system pre-calculates and pre-positions microwave sources and workpiece transport to ensure optimal alignment before microwave irradiation begins. The control unit coordinates the timing and positioning so that microwave energy is applied at the most effective moment and location, maximizing energy absorption before the workpiece moves out of the irradiation zone.
Solution Approach 2:
The device uses the natural attenuation of microwave energy through the workpiece itself as a protective mechanism. By optimizing the workpiece transport speed and microwave power density, the system ensures that microwave energy is fully utilized within the treatment zone, and any residual energy exiting the device is already significantly reduced, converting the potential harm of radiation into beneficial heating effect within the workpiece.
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 approach significantly increases the proportion of microwave energy absorbed by the workpiece, enhances energy efficiency, and prevents unwanted effects on surrounding components, enabling the crosslinking of a wider range of materials, including those with low microwave absorption.
Implementation Method 1
a monomode applicator into which microwaves from the microwave source can be coupled, wherein the at least one monomode applicator has a first opening for inserting and removing the workpiece
Implementation Method 2
a device for crosslinking one or more polar materials contained in a workpiece, in particular rubber, by means of microwaves
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to an apparatus (1) for cross-linking one or more, particularly polar, materials, particularly rubber, contained in a workpiece (3), by means of microwaves, with which apparatus a high degree of efficiency and good control over the microwave field arising in the apparatus (1) are achieved with at least one microwave source. According to the invention, the apparatus has at least one monomode applicator (4) into which microwaves from the microwave source can be coupled, wherein the at least one monomode applicator (4) has a first opening (20a) for introducing and removing the workpiece (3).