Squeezing-Roll Granulator with Three-Zone Tooth Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing squeezing roller granulators are unable to produce and seal granulate cushions with a covering and portioned filler, and the complex design of coextrusion methods for multilayer containers limits economically viable production to larger sizes, while also failing to enclose precisely portioned filler amounts in a media-tight fashion.
Innovation Solution
A squeezing roller granulator with a toothed pressure roller and toothed squeezing roller pair, featuring tooth flanks between a tooth root and tip region, with three squeezing zones that define different distances from the cylindrical pressure roller, allowing for the enclosure and sealing of multiple filler portions in granulate cushions, and enabling precise portioning and media-tight sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional squeezing roller granulator with uniform tooth design is used, then the device structure is simple, but it cannot produce granulate cushions with sealed filler portions
Solution Approach 1:
The roller tooth is segmented into three distinct zones along the circumferential direction: a first zone with a first tooth flank angle for filling, a second zone with a second tooth flank angle for sealing, and a third zone with a third tooth flank angle for discharge. This segmentation allows each zone to perform a specific function, enabling the granulator to produce sealed granulate cushions while maintaining a relatively simple overall structure.
Solution Approach 2:
Different regions of the roller tooth are given different geometric properties (tooth flank angles) suited to their specific functions. The first zone has a larger included angle for efficient filling, the second zone has an optimized angle for sealing, and the third zone has a smaller angle for discharge. This local differentiation of properties enables the single roller to perform multiple functions that would otherwise require separate components.
2Adaptability or versatility
If coextrusion method with filling mandrel is used to produce multi-layer containers, then granulate cushions can be filled, but the device design becomes complex and production is only economically viable from certain container sizes
Solution Approach 1:
The invention merges the filling, sealing, and portioning functions into a single squeezing roller granulator operation. The three-zone tooth design allows the roller to simultaneously perform filling (first zone), sealing (second zone), and portioning (third zone) in one continuous process, eliminating the need for separate molding and filling operations required by the coextrusion method with filling mandrel.
Solution Approach 2:
The squeezing roller is designed as a multi-functional component that can handle filling, sealing, and portioning of filler materials in a single operation. This universal design allows the same device to process various container sizes and filler types without requiring complex changeovers or additional equipment, making production economically viable across different scales.
3Manufacturing precision
If conventional squeezing roller design is used, then the structure is simple, but it cannot enclose precisely portioned filler amounts in a media-tight fashion
Solution Approach 1:
The tooth flank angles are optimized to create dynamic compression and release zones during the rolling operation. The varying angles create changing contact pressures that dynamically mold and seal the filler portions, ensuring precise portioning and media-tight sealing. The dynamic nature of the compression process allows for consistent precision across different filler materials and container sizes.
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 granulator can enclose twice as much filler in each granulate cushion compared to previous designs, produce symmetrically shaped cushions, and achieve media-tight sealing, facilitating mass production of granulate cushions with precise filler portions, including small volumes, and reducing wear on the rollers for extended operation.
Implementation Method 1
the radially outer surface regions of the projections should almost come to rest against the pressure roller so that in this position, the roller is held at a stop with a prestressing force and the plastic material of the plastic strand is broken down into granulate
Implementation Method 2
Radially outer ends of the squeezing roller cooperate with a smooth, cylindrical surface of the pressure roller
Data Source
AI summary
A squeezing roller granulator that has a squeezing roller pair composed of a toothed pressure roller and a toothed squeezing roller. The teeth of the pressure roller and the squeezing roller have tooth flanks that are situated between a tooth root region and a tooth tip region. The tooth root region has an outer diameter that is smaller than the outer diameter of the tooth tip region, and the tooth tip region of at least one of the rollers of the squeezing roller pair has three squeezing zones including a middle squeezing zone, which define different distances between the tooth tip regions with a minimum distance in the region of the middle squeezing zone, and the contour of the tooth flanks and the tooth root region of the rollers of the squeezing roller pair defines a maximum cross-section of granulate cushions to be formed.