CA1176015A - Method and apparatus for cooling molten tube - Google Patents

Method and apparatus for cooling molten tube

Info

Publication number
CA1176015A
CA1176015A CA000390856A CA390856A CA1176015A CA 1176015 A CA1176015 A CA 1176015A CA 000390856 A CA000390856 A CA 000390856A CA 390856 A CA390856 A CA 390856A CA 1176015 A CA1176015 A CA 1176015A
Authority
CA
Canada
Prior art keywords
steam
tube
molten
cooling
air
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000390856A
Other languages
French (fr)
Inventor
Ajit Bose
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Industries Leco Inc
Original Assignee
Leco Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Leco Inc filed Critical Leco Inc
Priority to CA000390856A priority Critical patent/CA1176015A/en
Application granted granted Critical
Publication of CA1176015A publication Critical patent/CA1176015A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25Component parts, details or accessories; Auxiliary operations
    • B29C48/88Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911Cooling
    • B29C48/9115Cooling of hollow articles
    • B29C48/912Cooling of hollow articles of tubular films
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils

Abstract

ABSTRACT OF THE DISCLOSURE Thin invention provides an improvement in a method of cooling molten extruded tube produced by a blown-tube process. The improvement comprises cooling the tube utilizing the heat of evaporation of moisture in steam. The steam is brought into contact with the molten tube after extrusion of the molten tube from an extrusion die, whereby the steam is permitted to expand prior to, during or subsequent to contact with the molten tube. An apparatus is also provided for carrying out the above-described method.

Description

3~.5 This invention relates to a method and apparatus for cooling a molten tube.
More particularly, this invention relates to a method of cooling a molten tube, and to an apparatus for carrying out such a method, in the process of extruding film-forming materials in what is commonly known as the blown-tube process.
The manufacture of film from plastic materials such as polyethylene is commonly carried out today by extruding film-forming resins in the "blo~n-tube" process. This process may be briefly summarized by saying that extrudable film-forming resin is introduced into an extruder where it is mixed and rendered molten, and the molten material subsequently passed through a die to form a bubble utilizing differential air pressure. The actual details of the blown tube method are well known to those skilled in the art and reference may be had to numerous publications and patents - for example, Canadian Patent 460,963.
As is evident from the above discussion, the resin material, in the form of a bubble, as it emerges from the extrusion die has a diameter normally smaller than that desired in the final product. The expansion of the bubble requires a differential air pressure between the inside of the bubble and the atmospheric pressure into which it is extruded to provide a film of the desired thickness which is achieved by controlling the air pressure in conjunction with the ' amount of resin extruded, etc. The tube or bubble, in the . _ _, ....... _ .... _ ... _ Ç^,?~ . S

direction of travel from the extrusion die, eventually solidifies from a molten mass to a solid ~ i.e., the lower portion of the tube or bubble is molten while the upper portion is solidified and the point at which the bubble actually solidifies is known as a "frost line".
For many reasons, the cooling of the bubble is a critical factor in the production of film such as from poly-ethylene resin. It is well known to those skilled in the art that the cooling rate can influence the quality of the product as to uniformity of film thickness, production capacity, etc. Normally, the molten tube, under today's technology, is subjected to one or more cooling zones using an annular flow of a gaseous cooling medium, such as air, which substantially surrounds the molten tube just downstream of the die. In most cases, the flow of the cooling gaseous medium is in a direction and in an amount sufficient to cause the bubble to be drawn outwardly towards the flow of the gaseous medium, so as to expand the diameter of the molten bubble and increase the size of the tube or film being produced.
The manner in which the cooling of the molten tube is carried out has also been changed over the years from the use of ordinary room-temperature air in the earlier times -to the use of refrigerated air in large scale plants. The use of chilled or refrigerated air for cooling the molten bubble requires, of course, the expenditure of energy to produce the cooled air r which is normally produced by refrigeration 3.5 systcms or similar means. The amount of energy required ror producing cooled air is quite significant having regard to the fact that relatively large volumes of cooled air are required for carrying out the cooling of the molten tube. In addition, the use of cooled air around an extruder, even with insulation of the apparatus, is not that efficient since the air itself is uscd in a "hot" environment - i.e., the surrounding ambient atmosphere and components of the extrusion apparatus are normally at siqnificantly elevated temperatures since the extrusion process relies on heat to produce the molten resin which is otherwise formed into a bubble.
With this invention, applicant has found that improved cooling can be obtained in a ~lown-tube process by utilizing, in direct contrast to the prior art, a source of steam, which may be saturated steam, for cooling the molten tube following extrusion from the extrusion die. More particularly, in accordance with the process of this invention, there is provided an improvement in a method of cooling molten extruded tube, produced by the blown--tube process, in which the improvement comprises cooling said tube utilizing the heat of evaporation of the moxi-ture in the steam by bringing said steam into contact with said molten tube after extrusion of the molten tube from the extrusion die; whereby said steam is permitted to expand prior to, during or subsequent to contact with said molten tube.

_.,.. ,.. _ . , , ... ~. . , __ ._.. . . . _.. _ _ ., , ~ ~7~ 1 5 In a still further aspect of this invention, there is provided an apparatus for cooling an extruded molten tube in which the apparatus comprises air ring means adapted to surround a molten extruded tube produced by a blown-tube process in which a molten tube is extruded from an extrusion die, steam generating means for generating a source of steam, means for operatively associating said steam generating means with said air ring means to feed a stream of steam into said air ring means, said air ring means comprising means for dispensing an annular flow of steam surrounding said molten extruded tube for permitting said steam to expand prior to, during, or subsequent to contact with said molten tube, whereby said steam is effective to cool said molten tube.
In greater detail, the process and apparatus for steam-cooling a molten tube utilizes the heat differential between the steam and the temperature of the melt (the molten tube) following extrusion. To this end, suitable steam-generating apparatus is employed in which a source of steam is generated; the steam generating apparatus may be any conventional steam generating apparatus which generates steam, which may be in a saturated stealn conditioil.

. _ . .. _ ., Th~ clloic~ of~ usincJ saturated steam will be depen~ent on several factors which include, for example, the capacity of cooling required for a particular type of resin, the melt temperature, and the degree of cooling desired (i.e., whether cooling is desired as quickly as possible or more slowly), etc. Typical steam-generating apparatus may include appropriate valve means for controlling the amount of steam;
likewise, there is normally associated with such steam-generating means, inlet means for providing a source of air, outlet means for delivering a supply of steam, the outlet means being operatively associated with the air ring means, and means for supplying a supply of moisture or water to the steam-generating means. The inlet means for the steam-generator, or the steam-generator per se, may be provided with suitable means for supplying a source of air, normally ambient air, under pressure so as to provide a desired air flow from the steam-generating means to -the air ring means. Typically, such means will comprise compressor means or the like, supplying air and the resultant steam from the steam-c3Oneratol-to the air ring means. In preferred forms of the apparatus of the present invention, and for carrying out the process involved therewith, the steam-generating means will supply a source of steam under high velocity, typically measured as a static pressure measurement equalling 10 to 15 inches of water. The larger extrusion die set-ups which are employed in the art today will generally use higher velocities measuring from 14 to 15 inches of water and extending upwards to 2~ or 25 inches of water, depending on the type of die. In single .. . . . . . . . _ . _ . .. ..

air rings, which are utilized on smaller extrusion dies for older e~uipment, the air velocity will measure as low as 4 to 5 inches of water.
The apparatus of the present invention, insofar as it includes the air ring means surrounding an extrusion die, may typically be enclosed in a housing or enclosed chamber, i order to control the amount of steam or moisture containing atmosphere surrounding the extrusion process. Thus, for example, an enclosed housing, preferably of transparent material such as the material marketed under the trademark "PLEXIGLASS", may be employed to surround the air ring means and extend upwardly of the bubble a suitable distance (preferably above the frost line); the housing preferably forms a chamber which retains the moisture-laden atmosphere produced by the steam-g~nerating means after the steam has been utilized for cooling purposes; means for removing the moisture-laden atmosphere may be employed for evacuating the chamber and for removing the moisture-laden atmosphere therefrom. To this end, a simple air evacuation pump may he connected to the chamber and if desired, the air evacuated from the chamber may be recycled to feed the same back into the steam-generating means to form a closed loop system.
Preferably, the moisture laden atmosphere which is spent is removed as soon as possible after utilization; means may be provided surrounding the lower portions of the enclosed housing and/or operatively associated with the air ring means and/or associated with the extrusion die, for removing con-densed moisture from the chamber or any area in proximity ... .. . ..

to the extrusion die or air ring - for example, in the case of condensation of any of the moisture from the spent atmosphere, the housing may be provided with a collecting surface connected to a conduit which in turn is either discharged or recycled through the steam-generating means for subsequent use in the steam-generating means.
., , In carrying out the process of this invention and for use with the apparatus described above, any suitable air ring means may be employed ranging from single air ring means to two or more of such air ring means. For example, as disclosed in Canadian Patent 922,063, two air rings may be employed to provide additional cooling capacity from the steam. The air ring means per se do not form any part of this invention except that in utilizing the air ring means, the air ring means comprises an annular ring (at least one) capable of dispersing or dispensing a supply of steam, preferably under high velocity conditions, into contact with the molten tube, whereby the stearn is permitted to expand, prior to, during or subsequent to contact with the molten tube following extrusion of the molten tube from the extrusion die. In a preferred form, the air ring means is preferably constructed so as to direct a source of steam into contact with the molten tube following expansion of the steam after release from the air ring means, the point of contact with the molten tube being less than 90 and significantly greater than 10, when measured in the axial direction of movement of the molten tube.

In the process of the present invention, as outlincd above, the steam is permitted to expand after issuing from thc lips of the air ring and following expansion of the steam, and due to expansion thereof, the moisture in the steam con-denses from the steam and since the steam is in contact with the molten extruded tube, the moisture is caused to evapora~e resulting in cooling of the molten tube. Thus, the moisture in the steam condenses in the form of droplets and it is these droplets of moisture, in contact with the molten tube, which evaporate and permit the cooling effect to occur on the molten -tube. Thus, typically with a low density polye-thylene, a melt temperature of 320F. - 380F. is employed so that the molten tube is extruded from the die lips at or about these temperatures. Steam, utilizing a steam-generator, may be generated under gaseous flow conditions of, e.g., 1000 c.f.m.
or less, and steam issuing from the air ring means at 212F., brought into contact with the molten tube, provides a tempera-ture differential, after expansion, of, e.g., 180F. when -the mclt tclnl,c~ tnre is 400~ or irl otller wordL;, lll( (oolin capacity o~ the steam at that ~oint undcr those condition~
is a~i~roxilnately 180 F.
In general, it is preferred -to utilize steam which is saturated to increase the cooling capacity for any given process conditions. It has been found that the heat transfer efficiency using saturated steam for a hot fluid versus a cold fluid is best and most efficiently employed under saturated ~ _ .. . . .. .. _ . . . _ _ _ . ~ . _ _ .

s _ 9 _ steam conditions so that the latent heat of evaporation of the moisture is more effectively utilized when employing saturated steam. To those skilled in the art, depending on the particular resin chosen and which is being extruded, as to the melt temperature, steam, or saturated steam, will have varying capacities to cool the molten tube and the appropriate degree of saturation of the steam may be chosen for opti~izing the cooling conditions under measurements well known by those skilled in this art - for example, reference may be had to "The Properties of Dry Saturated Steam", ~f the publication taken from "The 1939 Callendar Steam Tables".
The advantage of employing the process of the present invention is that, e.g., when employing saturated steam at 212F., and a typical melt temperature of 350 - 400 F. for a low density polyethylene resin, a cooling capacity of 130 F. - 180 F.
is obtained; to obtain a similar cooling capacity utilizing refrigerated air, it will be seen that the refrigerated air must be lowered by a similar amount which requires the use of a significant energy expenditure compared to the process of the present invention.
It will be understood that various modifications can be made to the above-described embodiments without departing from the spirit and scope of the invention as described herein.

Claims (13)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. In a method of cooling molten extruded tube produced by a blown-tube process, the improvement comprising cooling said tube utilizing the heat of evaporation of moisture in steam by bringing said steam into contact with said molten tube after extrusion of the molten tube from an extrusion die, whereby said steam is permitted to expand prior to during or subsequent to contact with said molten tube.
2. A method as defined in Claim 1 wherein said steam is saturated steam.
3. A method as defined in Claim 1 wherein said steam is applied to the molten tubing following extrusion of the molten tubing, said steam being applied substantially about the circumference of the tube.
4. A method as defined in Claim 3 wherein said steam is applied immediately after the molten tube is extruded from an extruder die.
5. A method as defined in Claim 1 wherein the steam is applied at more than one stage whereby at least primary and secondary cooling of the molten bubble is obtained.
6. A method as defined in Claim 1 wherein said steam is applied under gaseous flow conditions of more than 1000 c.s.m.
7. A method as defined in Claim 1 wherein the point of contact of the steam with the tube is greater than 10° and less than 90° relative to the axial direction of movement of the tube.
8. An apparatus for cooling an extruded molten tube comprising air ring means adapted to surround a molten extruded tube produced by a blown-tube process in which a molten tube is extruded from an extrusion die, steam generating means for generating a source of steam, means for operatively associating said steam generating means with said air ring means to feed a stream of steam into said air ring means, said air ring means comprising means for dispensing an annular flow of steam surrounding said molten extruded tube for permitting said steam to expand prior to, during, or subsequent to contact with said molten tube, whereby said steam is effective to cool said molten tube.
9. An apparatus as defined in Claim 8 wherein said apparatus includes air supply means for supplying a source of pressurized air.
10. An apparatus as defined in Claim 9 wherein the source of pressurized air is fed to said steam generating means.
11. An apparatus as defined in Claim 8 wherein the steam generating means comprises means for generating saturated steam.
12. An apparatus as defined in Claim 8 wherein there are included two or more air rings to provide at least primary and secondary cooling.
13. An apparatus as defined in Claim 8 wherein said air ring means includes air ring lips for permitting said steam to expand upon issuing from said air ring means and wherein said lips are adapted to direct said steam into contact with said molten tube at an angle greater than 10°
but less than 90° relative to the axial direction of movement of said molten tube.
CA000390856A 1981-11-25 1981-11-25 Method and apparatus for cooling molten tube Expired CA1176015A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000390856A CA1176015A (en) 1981-11-25 1981-11-25 Method and apparatus for cooling molten tube

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000390856A CA1176015A (en) 1981-11-25 1981-11-25 Method and apparatus for cooling molten tube

Publications (1)

Publication Number Publication Date
CA1176015A true CA1176015A (en) 1984-10-16

Family

ID=4121492

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000390856A Expired CA1176015A (en) 1981-11-25 1981-11-25 Method and apparatus for cooling molten tube

Country Status (1)

Country Link
CA (1) CA1176015A (en)

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Effective date: 20011125