Continuous Panel Forming Apparatus for Cooling Tower Production
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Solution Overview
Problem
Existing panel manufacturing technologies for cooling towers result in microfractures leading to microparticle pollution and are limited by dimensional constraints, requiring inefficient and costly production processes.
Innovation Solution
A continuous panel forming apparatus that uses a die and counterdie system with coordinated movement to produce corrugated sheets, eliminating gaps at edges and allowing for large-scale, efficient production without pauses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermoforming and vacuum plants are used to manufacture panels, then panels can be produced with predetermined dimensions, but microfractures occur at cut edges causing panel disaggregation and microparticle pollution
Solution Approach 1:
The invention divides the panel manufacturing process into continuous sequential stages: feeding the polymeric band, heating it to plastic deformation temperature, forming it between die and counterdie with coordinated movement, and cooling it. This segmentation eliminates the need for post-manufacturing cutting operations that cause microfractures, as panels are produced in their final dimensions directly from the continuous band.
Solution Approach 2:
The invention performs preliminary heating of the polymeric band to its plastic deformation temperature before forming. This preliminary thermal preparation allows the material to be shaped without subsequent cutting operations, preventing microfracture formation at edges while maintaining manufacturing precision.
2Manufacturing precision
If conventional batch processing methods are used, then panels can be manufactured within dimensional limits, but production is slow and requires multiple machines with long cycle times
Solution Approach 1:
The invention implements continuous processing where a polymeric band is fed continuously through heating and forming zones without interruption. The die and counterdie move in coordinated fashion along the band's length, enabling continuous formation of panels with precise dimensional control while dramatically increasing production speed compared to batch methods.
Solution Approach 2:
The invention transitions from two-dimensional batch processing on fixed machines to three-dimensional continuous processing along the length of the polymeric band. The die and counterdie traverse along the band's longitudinal dimension, enabling multiple panels to be formed simultaneously in sequence, thereby increasing productivity while maintaining precision.
3Manufacturing precision
If panels are produced with cut edges from conventional processes, then dimensional limits can be achieved, but panel reliability decreases due to microfractures during normal operation
Solution Approach 1:
The invention extracts and eliminates the harmful cutting operation from the manufacturing process. By forming panels directly to final dimensions through continuous forming between die and counterdie, the process removes the source of microfractures at cut edges, thereby maintaining dimensional precision while significantly improving panel reliability and preventing disaggregation during operation.
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 apparatus prevents panel disaggregation and enables quick, cost-effective manufacturing of large panels with enhanced thermal exchange efficiency.
Implementation Method 1
the die and the counterdie are pressed, one against the other, to form a panel by deforming a polymeric band
Implementation Method 2
a heating zone arranged upstream the die, which is configured to heat the band with a quantity of heat sufficient to make the band deformable
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An apparatus (4) for forming a panel (1) and designed to receive a flat strip (2') along a longitudinal direction (2a), is disclosed comprising: a die (5) including a plurality of first tracks (50) movable along a first path (5a) and consecutively arranged so as to make at least a first forming surface (51) at least at a first segment (s') of said first path (5a) parallel to said longitudinal direction (2a); a counterdie (6) including a plurality of second tracks (60) movable along a second path (6a) and consecutively arranged so as to make a second forming surface (61 ) countershaped with said first forming surface (51) at least at a second segment (s") of said second path (6a) parallel to said longitudinal direction (2a); first movement means (7) configured to move said first tracks (50) along said first path (5a); and second movement means (8) configured to move said second tracks (60) along said second path (6a); said movement means (7,8) being further configured to move said tracks (50, 60) simultaneously in a coordinated way in the same direction, at least when corresponding with said segments (s', s); and said segments (s', s") being mutually opposite, so that their forming surfaces (51, 61) always interpenetrate mutually pressing and moving, in use, along said longitudinal direction (2a) by said forming surfaces (51, 61 ), said strip (2') introduced between said die (5) and counterdie (6), thus producing said panel (1 ).