Tenter Oven Airflow Controller for Film Temperature Uniformity
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Solution Overview
Problem
The existing methods for controlling air flow in tenter ovens during the manufacturing of stretched films made of thermoplastic resin suffer from temperature unevenness, energy inefficiency, and environmental pollution due to uncontrolled air flows, leading to product quality issues and increased energy consumption.
Innovation Solution
An air flow controller with a box-shaped body cover and partition structural bodies that separate the air flow into chambers with independent air discharge mechanisms, allowing for the adjustment of flow rates and direction to prevent external cold air from entering and hot air from escaping, thereby maintaining uniform film temperature and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air flow is not controlled in the tenter oven, then the structure remains simple, but temperature unevenness occurs and energy consumption increases
Solution Approach 1:
The air flow controller divides the air flow control into multiple independent chambers (first chamber and second chamber) with separate air discharge mechanisms. Each chamber can independently adjust air discharge flow rates, allowing precise control of air flow in different regions of the tenter oven to eliminate temperature unevenness without requiring a completely complex system redesign
Solution Approach 2:
The patent implements different air discharge flow rates in different chambers to address local temperature issues. The first air discharge mechanism and second air discharge mechanism can operate with different flow rates tailored to the specific heating requirements of their respective zones, optimizing temperature uniformity locally while maintaining overall system simplicity
2Loss of energy
If air flow is not controlled, then the device operates simply, but energy consumption increases due to cold air inflow and hot air outflow
Solution Approach 1:
The air flow controller extracts and separately controls the air discharge function from the general heating system. By providing dedicated air discharge mechanisms in specific chambers, the system can selectively remove excess air and prevent energy loss from uncontrolled air exchange, reducing energy consumption without requiring complete system restructuring
Solution Approach 2:
The independent air discharge mechanisms in each chamber enable feedback control of air flow based on local conditions. By monitoring and adjusting air discharge flow rates in response to temperature and pressure variations, the system minimizes energy loss from cold air inflow and hot air outflow while maintaining operational simplicity
3Object-affected harmful factors
If high temperature air is allowed to escape to the outside, then the tenter oven ventilation is simple, but the surrounding temperature increases and work environment deteriorates
Solution Approach 1:
The air flow controller converts the potentially harmful hot air escape into a controlled process. By using the air discharge mechanisms to manage air flow, the system prevents uncontrolled hot air release that would increase surrounding temperature, while the discharged air can be managed or recirculated, turning a harmful effect into a controllable parameter
4Productivity
If air flow is not controlled, then the system operates simply, but productivity decreases due to film breakage and quality deterioration
Solution Approach 1:
By segmenting the air flow control into multiple independent chambers with separate discharge mechanisms, the system provides precise local control that prevents film breakage and quality issues. This segmented approach improves productivity by ensuring uniform temperature distribution without requiring an overly complex monolithic control system
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 air flow controller effectively reduces temperature unevenness, ensures uniform film characteristics and thickness, decreases energy consumption, and prevents environmental pollution by controlling air flow within the tenter oven, enhancing both product quality and operational efficiency.
Implementation Method 1
A phenomenon exists in which air flows in a film running direction due to a pressure difference between the exit and the entrance or between zones of the tenter oven
Implementation Method 2
Film temperatures at the respective processes can be adjusted by blowing air preliminarily heated to respective desired temperatures to the film via blowing nozzles
Data Source
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AI summary
In the present invention, an air flow controller is disposed adjacent to an upstream side of an entrance of a tenter oven and/or a downstream side of an exit of the tenter oven. The air flow controller includes a box-shaped body cover that extends in a film running direction and has a surface facing a film running surface and being open. The box-shaped body cover includes at least one partition structural body extending in a film width direction inside the box-shaped body cover. The partition structural body separates the box-shaped body cover into a plurality of chambers. Air discharge mechanisms included in at least two of the chambers discharge air to the outside.