Non-Contact Heat Setting Machine for Spiral Mesh Shrinkage Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat setting processes for spiral meshes, particularly those with large thickness or multi-layer structures, face challenges in controlling thermal shrinkage and preventing crinkling due to the inability to apply non-contact heating methods without damaging the mesh surface.
Innovation Solution
A non-contact setting machine and method that utilizes a conveying mechanism, heating mechanism, visual collectors, and control device to monitor and adjust the mesh's surface tension, temperature, and shape, ensuring controlled thermal shrinkage and preventing crinkling through real-time feedback loops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If contact heat setting by heating roll is used, then heat setting can be achieved, but heat penetration ability is insufficient for thick or multi-layer spiral meshes
Solution Approach 1:
The patent transitions from single-sided contact heating to multi-dimensional non-contact heating by arranging heating rolls both above and below the spiral mesh, enabling heat to penetrate from multiple directions simultaneously, thus solving the insufficient heat penetration for thick or multi-layer structures
Solution Approach 2:
The patent replaces the mechanical contact heating system with a non-contact heating system using infrared radiation or electromagnetic fields, eliminating the need for physical contact while achieving superior heat penetration and uniformity across the entire mesh surface
2Force
If pin stenter is used for forced stentering, then width direction restriction can be provided, but irreversible damage occurs to the spiral mesh surface
Solution Approach 1:
The patent replaces the mechanical pin stenter system with a non-contact heating system that provides uniform thermal restriction without physical contact, eliminating surface damage while maintaining the necessary tension control through controlled thermal shrinkage
Solution Approach 2:
The patent changes the heating parameters by using non-contact infrared or electromagnetic heating with controlled temperature distribution, allowing uniform thermal shrinkage restriction without the mechanical damage caused by pin stentering
3Shape
If no external force restriction is applied, then the spiral mesh structure is preserved, but excessive shrinkage and crinkling occur
Solution Approach 1:
The patent changes the thermal parameters by using non-contact heating with precisely controlled temperature distribution and heating duration, enabling uniform thermal shrinkage that maintains mesh structure integrity while preventing excessive shrinkage and crinkling
Solution Approach 2:
The patent implements a feedback control system that monitors the heat setting process in real-time and adjusts heating parameters dynamically, ensuring uniform shrinkage control while preserving the spiral mesh structure and preventing defects
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 effectively controls thermal shrinkage and prevents crinkling of spiral meshes, enhancing the quality and efficiency of the heat setting process by ensuring uniform heating and tension adjustment.
Implementation Method 1
a heating mechanism capable of defining a heating area for the spiral mesh to pass through
Implementation Method 2
heat setting is crucial, which can improve the molecular crystallinity and orientation in the spiral mesh
Implementation Method 3
a conveying mechanism capable of driving a spiral mesh to rotate
Implementation Method 4
a first visual collector and a second visual collector which are located on inlet and outlet sides of the heating mechanism and used to collect visual information of the spiral mesh
Data Source
AI summary
A non-contact setting machine for heat setting of a spiral mesh, and a setting method includes a conveying mechanism for driving a spiral mesh to rotate, a heating mechanism for defining a heating area for the spiral mesh to pass through, and a first visual collector and a second visual collector located on inlet and outlet sides of the heating mechanism. A control device receives visual information of the spiral mesh collected by the first and second visual collectors; the conveying and heating mechanisms are separately connected to the control device by lines; the control device controls and adjusts the conveying mechanism rotating speed and/or the spiral mesh surface tension and/or the heating mechanism temperature. The setting machine and method achieve upper- and lower-layer non-contact heat setting of the spiral mesh and can control the shrinkage range of the mesh surface of the spiral mesh, thus avoiding crinkling.