Toothed Squeezing Roller Granulator with Multi-Zone Nip
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Solution Overview
Problem
Existing granulator devices are unable to efficiently produce granulate cushions with a coating and portioned filling compound, and they struggle with mass production of precisely portioned filling materials in a media-tight manner.
Innovation Solution
A squeeze roller granulator with a cylindrical pressure roller and a toothed squeezing roller featuring three nip zones with different distances to the pressure roller, allowing for the formation and sealing of granule pillows with a coextruded filling compound, and incorporating a feed device for casing tubes with a coextruded filling compound to achieve media-tight sealing and portioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional granulator devices are used to separate pre-solidified strands into plastic granules, then granule production is achieved, but the ability to produce granulate cushions with coating and portioned filling compound is lost
Solution Approach 1:
The squeezing roller is divided into three distinct nip zones (first, second, and third) with different gap distances, allowing each zone to perform a specific function: the first zone for initial compression and sealing, the second zone for maximum compression and portioning, and the third zone for final sealing. This segmentation enables the single device to handle both the coating and filling compound portioning functions simultaneously, achieving versatility without sacrificing mass production capability
Solution Approach 2:
The invention transitions from a conventional single-gap granulator design to a multi-dimensional approach by creating three nip zones with progressively varying gap distances along the rotational path of the squeezing roller. This dimensional variation in gap distance allows the device to perform multiple operations (compression, sealing, portioning) in sequence within a single rotational cycle, enabling mass production of complex granulate cushions with filling compounds
2Manufacturing precision
If coextrusion process with filling mandrel is used to produce multi-layer plastic container with filling compound, then granulate cushions with portioned filling material are achieved, but device complexity increases
Solution Approach 1:
The squeezing roller with three varying nip zones serves multiple functions that would traditionally require separate devices: it compresses the coating and filling compound, creates media-tight seals, portions the filling material, and forms the final granulate cushion shape. This multi-functionality is achieved within a single roller component, avoiding the need for complex multi-step processes with filling mandrels and multiple sealing devices
Solution Approach 2:
The coextrusion process preliminarily forms the filling compound within the coating structure before it reaches the squeezing roller. The three nip zones then continue this preliminary work by progressively compressing and sealing the material, completing the portioning process without requiring additional filling mandrels or complex assembly steps
3Reliability
If conventional squeezing roller with uniform tooth tip area is used, then simple structure is maintained, but media-tight sealing and precise portioning of filling materials cannot be achieved
Solution Approach 1:
The tooth tip area is designed with non-uniform properties: the first tooth tip region has a larger surface area and smaller gap distance for aggressive compression and initial sealing, while the second and third tooth tip regions have progressively smaller surface areas and larger gap distances for refined portioning and final sealing. This local variation in tooth geometry allows each region to optimize its function, achieving media-tight sealing and precise portioning without requiring complex external mechanisms
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 the mass production of granulate cushions with media-tight sealing and precise portioning of filling materials, overcoming the limitations of previous systems in producing granulate cushions with coextruded filling compounds.
Implementation Method 1
the contour of the tooth flanks and the tooth base area of the nip roller interact with the contour of the cylindrical pressure roller maximum cross-section of the granulate cushion to be formed is defined
Data Source
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AI summary
Squeezing-roll granulator (1) which has a cylindrical pressure roll (2) and a toothed squeezing roll (3), wherein the toothing (4) of the squeezing roll (3) has tooth flanks (5, 6) which are arranged between a tooth root region (7) and a tooth crown region (8), and wherein the tooth root region (7) has an external diameter (d) which is smaller than the external diameter (D) of the tooth crown region (8), and wherein the tooth crown region (8) of the squeezing roll (3) has three squeezing zones (9, 10, 11) with a central squeezing zone (10) which define different spacings from the cylindrical pressure roll (2) with a minimum spacing (a) in the region of the central squeezing zone (10), and wherein the contour of the tooth flanks (5, 6) and of the tooth root region (7) of the squeezing roll (3) defines a maximum cross section of granulate cushions (12) in interaction with the contour of the cylindrical pressure roll (2).