Moving Manifold Cooling for Polymer Mold Heat Transfer
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Solution Overview
Problem
Existing cooling systems for moving molds in corrugated polymer pipe manufacturing are inefficient, unreliable, and often interfere with vacuum mechanisms, limiting the manufacturing rate due to inadequate heat transfer.
Innovation Solution
A mold cooling system featuring a moving manifold with a cooling fluid supply and return, integrated into the mold housing with passageways for efficient heat transfer, utilizing a cooling fluid that flows through stainless steel tubes cast into the mold to absorb heat from the polymer and mold surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cooling systems are used for moving molds, then the manufacturing process can continue, but the cooling efficiency is insufficient and the system is unreliable
Solution Approach 1:
The cooling system is extracted from the moving mold and integrated into the stationary manifold system. The manifold remains fixed while the mold moves through it, allowing the cooling infrastructure to be separated from the moving component and placed in a more stable, serviceable location.
Solution Approach 2:
A stationary manifold acts as an intermediary between the cooling fluid supply and the moving mold. The manifold provides a stable interface that connects the fixed cooling infrastructure to the moving mold through flexible couplings or quick-connect mechanisms.
2Loss of energy
If cooling systems are added to moving molds, then heat transfer efficiency improves, but the system complexity increases and interference with vacuum mechanisms occurs
Solution Approach 1:
The cooling system is segmented into modular components: a stationary manifold, flexible connections, and mold-integrated cooling channels. This segmentation allows the cooling function to be added without complicating the mold structure itself, as the complex manifold infrastructure remains separate.
Solution Approach 2:
The cooling channels are merged with the mold cavity structure, with passageways extending through the mold housing adjacent to the mold surface. This integration allows efficient heat transfer without adding separate cooling apparatus that would increase complexity.
3Temperature
If longer residence time is used for cooling, then the polymer cools sufficiently, but the manufacturing rate decreases
Solution Approach 1:
The cooling approach moves from temporal extension (longer residence time) to spatial optimization (extended passageway network). By developing cooling passageways in multiple dimensions within the mold housing, sufficient cooling is achieved in the same residence time, maintaining high production rates.
Solution Approach 2:
The system changes the cooling parameter from time-based (residence time extension) to area-based (passageway surface area and proximity to mold surface). The extended passageway adjacent to the mold surface provides increased heat transfer area, achieving adequate cooling without extending the manufacturing cycle.
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 system effectively cools the polymer and mold surfaces, reducing deformation risks and enhancing manufacturing efficiency by rapidly cooling the polymer to a stable temperature before product release.
Implementation Method 1
a passageway that extends through the mold housing adjacent to the mold surface, the passageway connecting the cooling fluid supply and the cooling fluid return when the moving manifold is received in the connector
Data Source
AI summary
A mold cooling system is provided for cooling a polymer product shaped in a mold. The mold cooling system includes a moving manifold having a cooling fluid supply and a cooling fluid return; and a mold housing having a mold surface that defines a cavity. The mold housing has a connector configured to receive the cooling fluid supply and cooling fluid return of the moving manifold; and a passageway that extends through the mold housing adjacent to the mold surface, the passageway connecting the cooling fluid supply and the cooling fluid return when the moving manifold is received in the connector. A method is also provided for cooling an extruded, blow-molded product before the product is released from a mold.