Piston System with Segmented Lubrication and Cooling Channels
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Solution Overview
Problem
The existing piston systems used in pressure agglomeration for increasing elastomeric particle size suffer from frequent maintenance due to friction and wear caused by sticky slurries, leading to reduced production rates and downtime in continuous processes.
Innovation Solution
A piston system with separate supply channels for lubricating and cooling media, where the lubricating medium is applied internally and the cooling medium is applied externally to reduce friction and heat dissipation, preventing contamination and extending maintenance intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single supply channel is used for both lubricating and cooling media, then the device complexity is reduced, but the reliability deteriorates due to insufficient lubrication and cooling effectiveness
Solution Approach 1:
The single supply channel is segmented into two separate channels: a first supply channel for lubricating medium and a second supply channel for cooling medium. This segmentation allows independent optimization of lubrication and cooling functions, improving reliability without excessive complexity increase.
Solution Approach 2:
Different regions of the piston are provided with different media through separate channels: the first part inside the cylinder receives lubricating medium for friction reduction, while the second part outside the cylinder receives cooling medium for heat dissipation. This local quality differentiation optimizes each region's specific needs.
2Device complexity
If no lubricating medium is supplied to the piston, then the device complexity is reduced, but the reliability worsens due to friction and wear from sticky slurries
Solution Approach 1:
Lubricating medium is supplied to the piston before the sticky slurry causes excessive friction and wear. The first supply channel delivers lubrication proactively to the first part of the piston inside the cylinder, preventing damage before it occurs and extending maintenance intervals.
3Temperature
If the cooling medium is supplied inside the cylinder, then the cooling effectiveness is improved, but the manufacturing precision deteriorates due to contamination of the slurry
Solution Approach 1:
The cooling function is segmented from the cylinder interior to the exterior through a second supply channel. This separates the cooling medium's path from the slurry processing zone, preventing contamination while maintaining cooling effectiveness on the piston's second part.
Solution Approach 2:
The piston's second part acts as an intermediary heat transfer surface, allowing cooling medium to remove heat from the piston without directly contacting the slurry inside the cylinder. This mediator approach maintains slurry purity while achieving cooling objectives.
4Device complexity
If friction and wear are not reduced, then the device complexity is reduced, but the productivity deteriorates due to frequent maintenance and downtime
Solution Approach 1:
Lubricating medium is supplied in advance to reduce friction before wear occurs, and cooling medium is supplied to prevent overheating that could cause failures. These preliminary protective actions extend maintenance intervals and maintain continuous production, improving productivity.
Solution Approach 2:
The piston system performs self-lubrication and self-cooling through the supplied media, reducing the need for external maintenance interventions. This self-service capability minimizes downtime and maintains steady production rates.
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 piston system significantly reduces friction and wear, allowing for continuous operation with reduced maintenance frequency, thereby enhancing the production efficiency and stability of elastomer agglomerate compositions.
Implementation Method 1
a first supply channel that is configured and arranged to supply a lubricating medium to a portion of a first part of the piston that, in use, is arranged inside the cylinder
Implementation Method 2
a second supply channel that is configured and arranged to, in use, supply a cooling medium to a second part of the piston outside the cylinder
Implementation Method 3
supply a cooling medium to a second part of the piston outside the cylinder
Data Source
AI summary
The invention relates to a piston system (1) for use in a homogenizer, comprising a piston (2) that is configured and arranged to make a reciprocating movement in use of the piston system, a cylinder (3) that is configured and arranged to receive and guide at least a first part of the piston, a first supply channel (8) that is configured and arranged to supply a lubricating medium (9) to a portion (10) of the first part of the piston that in use is arranged inside the cylinder, and a second supply channel (13) that is configured and arranged to, in use, supply a cooling medium (14) to a second part of the piston outside the cylinder. Also disclosed is a process for the production of an elastomer agglomerate composition forcing a slurry comprising elastomeric particles through an aperture to obtain the elastomer agglomerate composition using the piston system.