Multi-stage Roll Sheet Molding for Uniform Cooling
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Solution Overview
Problem
Existing sheet molding apparatuses face challenges in efficiently cooling thick sheets at high speeds and maintaining quality, as they lack sufficient contact cooling distance and uniform cooling of both sheet surfaces, leading to uneven temperature distribution and reduced cooling capacity.
Innovation Solution
A multi-stage roll type sheet molding apparatus with four or more molding rolls, including a touch molding roll, a main molding roll, and multiple finish molding rolls, where the rolls are configured to provide increased contact cooling distance and uniform cooling through horizontal movement and adjustment of roll positions, and the use of elastic rolls to enhance flexibility and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If three molding rolls are used with traditional configuration, then the apparatus structure is simple, but the cooling distance is insufficient and cooling efficiency is low
Solution Approach 1:
The cooling process is segmented into multiple stages by introducing intermediate molding rolls between the touch molding roll and finish molding roll. This divides the single cooling path into multiple sequential cooling zones, extending the total cooling distance without proportionally increasing structural complexity. Each intermediate roll acts as an independent cooling stage, allowing progressive heat removal from the sheet.
2Device complexity
If three molding rolls are used with traditional configuration, then the apparatus structure is simple, but the number of cooling times is insufficient and temperature uniformity is poor
Solution Approach 1:
Different regions of the sheet receive differentiated cooling treatments through the multi-roll configuration. The touch molding roll provides initial cooling on one surface, intermediate rolls provide additional cooling stages, and the finish molding roll completes the cooling process. This localized, multi-stage approach ensures uniform temperature distribution across the entire sheet by addressing hot spots at different locations and stages.
3Productivity
If molding speed is increased for thin sheets, then productivity is improved, but cooling time becomes insufficient and quality deteriorates
Solution Approach 1:
The multiple molding rolls are configured to rotate at coordinated speeds, creating continuous contact with the sheet throughout its passage. This continuous multi-point contact ensures that cooling action is maintained without interruption throughout the entire molding process, allowing high molding speeds to be sustained while adequate cooling time is preserved through the extended contact path.
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 high-speed molding of both thin and thick sheets with improved cooling efficiency and surface quality, ensuring uniform heat distribution and enhanced gloss and transparency.
Implementation Method 1
the outer peripheral surfaces of the touch molding roll 101 and main molding roll 102 are simultaneously contacted with both sides of the sheet 105. Specifically, through the contact with the touch molding roll 101, the sheet 105 is cooled just instantly, whereas most of cooling of the sheet 105 is attained by the main molding roll 102.
Data Source
AI summary
A multi-stage roll type sheet molding apparatus includes four or more molding rolls including a touch molding roll, a main molding roll and finish molding rolls disposed in the horizontal direction in parallel to each other, in which a molten sheet is supplied downward from above to a first nip part interposed between the touch molding roll and main molding roll, the sheet is compressed by the molding rolls, and the compressed sheet is windingly fed sequentially from the main molding roll to the finish molding rolls, thereby molding a sheet having a specific thickness. The apparatus further includes a rear-stage side rail for guiding the finish molding rolls in a horizontally movable manner and second to fourth hydraulic cylinders for horizontally moving the finish molding rolls to in such a manner that they can pressurize the sheet.