Tapered Nozzle Plate for Uniform Fiber Oxidation Air Flow
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Solution Overview
Problem
Conventional oxidation ovens for producing carbon fibers face challenges in achieving uniform and parallel air streams due to misalignment of hex honeycomb material with nozzles, leading to increased manufacturing and assembly costs.
Innovation Solution
The oven design incorporates plenums with nozzle plates featuring tapered cross-sectional nozzles, eliminating the need for hex honeycomb material, which allows for uniform and parallel air streams without the complexity and cost of alignment, using thicker nozzle plates with curved or beveled edges to stabilize and redirect air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hex honeycomb material is added to reinforce thin nozzle sheets and control air flow direction, then uniform and parallel air streams are achieved, but manufacturing and assembly costs increase due to alignment difficulties
Solution Approach 1:
The patent removes the hex honeycomb material from the system entirely. Instead of using thin nozzle sheets reinforced with honeycomb material, the invention employs thicker nozzle sheets (at least 0.25 inches thick) that provide sufficient structural reinforcement on their own, eliminating the need for additional honeycomb layers and the associated alignment complexities.
Solution Approach 2:
The patent changes the thickness parameter of the nozzle sheets from less than 0.25 inches to at least 0.25 inches. This parameter change provides sufficient structural strength and flow control capability within the nozzle sheet itself, eliminating the need for external honeycomb reinforcement and reducing manufacturing complexity.
2Manufacturing precision
If two sheets of hex honeycomb material are added to each plenum to reinforce and control air flow, then air stream uniformity is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the hex honeycomb material entirely from the plenum structure. The thicker nozzle sheets (at least 0.25 inches thick) provide all necessary structural support and air flow control functions independently, removing the need for costly honeycomb material and its precise alignment during assembly.
Solution Approach 2:
By increasing the nozzle sheet thickness to at least 0.25 inches, the patent achieves sufficient structural reinforcement and flow control capability within a single component, eliminating the need for additional honeycomb layers and reducing overall manufacturing costs.
3Quantity of substance
If thin nozzle sheets are used, then material cost is reduced, but structural reinforcement and flow control require additional hex honeycomb material
Solution Approach 1:
The patent changes the nozzle sheet thickness from less than 0.25 inches to at least 0.25 inches. This single parameter change provides sufficient structural reinforcement and flow control capability within the nozzle sheet itself, eliminating the need for additional honeycomb material and reducing overall structural complexity.
Solution Approach 2:
The patent combines the functions of structural reinforcement and air flow control into a single thicker nozzle sheet component. This merging of functions eliminates the need for separate honeycomb reinforcement layers, simplifying the overall structure while maintaining all necessary capabilities.
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
This design ensures uniform and parallel air streams are maintained without the need for hex honeycomb material, reducing manufacturing costs and achieving consistent air flow without misalignment issues, while maintaining the same level of uniformity as previous designs.
Implementation Method 1
Each of the plurality of nozzles has a respective tapered cross-sectional shape
Data Source
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AI summary
One embodiment is directed to an oven for heating fibers. The oven comprises a supply structure disposed within the oven between first and second ends of the oven. The supply structure comprises a plurality of plenums stacked one above each other with gaps therebetween. The plenums are in fluid communication with a heating system. At least one plenum comprises at least one side wall comprising a plurality of passages formed therein, said at least one plenum configured to direct at least a portion of the heated gas into an interior of the oven from the plurality of passages. Each of the plurality of passages formed in said at least one plenum has a respective tapered cross-sectional shape.