Pressure Lock Sleeve-Piston Design for High-Pressure Extrusion
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Solution Overview
Problem
Existing technologies for introducing solids or bulk material into high-pressure processes face limitations in pressure difference capability (up to 3-4 bar) and often result in material alteration, degradation, or turbulent distribution due to sudden pressure changes.
Innovation Solution
A pressure lock system with a housing, sleeve, and piston design that allows controlled axial and rotational movements to alternately connect a material receiving space with charging and discharging openings, ensuring gradual pressure equalization and minimizing turbulent distribution, enabling continuous operation across significant pressure differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotary valves are used for introducing solids/bulk material into pressurized atmosphere, then throughput is very high, but maximum process pressure difference is limited to 3 to 4 bar
Solution Approach 1:
The introduction process is segmented into multiple stages: a pre-chamber is used to receive material at atmospheric pressure, then a piston gradually pressurizes the material in stages before discharge. This segmentation allows the system to overcome the pressure difference limitation of rotary valves while maintaining high throughput.
Solution Approach 2:
A pre-chamber acts as an intermediary between the atmospheric material source and the high-pressure extrusion zone. The piston-mediated pressurization process in the pre-chamber allows gradual pressure buildup, enabling material introduction at pressure differences exceeding 3-4 bar while maintaining continuous high throughput.
2Ease of operation
If material is introduced from lower pressure to higher pressure area, then material can be fed into pressure process, but sudden pressure changes cause turbulent distribution and material degradation
Solution Approach 1:
The piston performs preliminary pressurization action in the pre-chamber before material discharge. By gradually increasing pressure from atmospheric level to the required process pressure in controlled stages, the system eliminates sudden pressure changes that would cause turbulence and material degradation.
Solution Approach 2:
The piston-mediated pressurization process provides beforehand cushioning by gradually building up pressure in the pre-chamber. This controlled, staged pressurization cushions against sudden pressure shocks, preventing turbulent distribution and protecting material integrity during the transition from atmospheric to process pressure.
3Quantity of substance
If high-pressure pumps are used to feed solids/bulk material in suspensions, then small quantities can be fed, but size and quantity of solids/bulk material are limited
Solution Approach 1:
The system extracts solids/bulk material from suspension form and handles them as pure bulk material in the pre-chamber. This extraction from suspension allows much larger quantities and sizes of solid material to be fed directly into the pressurization process without the limitations of pump-based suspension feeding.
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 continuous high-pressure extrusion processes by maintaining consistent pressure within the extruder, preventing material degradation and turbulence, and allowing efficient material transfer between low and high-pressure environments.
Implementation Method 1
the cylindrical inner wall section of the housing and the cylindrical outer wall section of the sleeve form a pressured gas tight slide bearing between the material charging area and the material discharging opening allowing an axial movement of the sleeve with respect to the housing
Implementation Method 2
the cylindrical inner wall section of the sleeve and the first cylindrical outer wall section of the piston form a pressured gas tight slide bearing allowing an axial movement of the piston with respect to the sleeve
Data Source
Figure 1B~2B
Figure 3A~3E
Figure 4A~4E
AI summary
Pressure lock and extruding apparatus for high pressure extrusion with a pressure lock.