The invention relates to a furnace of the rotary type for conditioning preforms.
In the blow-moulding or stretch blow-moulding method containers are manufactured from so-called preforms which must be heated to a desired temperature before the actual blow-moulding stage. In order to be able to reshape the rotationally symmetrical preforms, which as a rule have standardised wall thickness values, during blow moulding into a container with a certain shape and wall thickness, individual wall sections of the preform are gradually heated in a furnace, preferably with infrared radiation. Normally, for this purpose a continuous flow of preforms is passed through a furnace with appropriately adapted irradiation sections. One problem with furnaces of this nature is however the targeted transfer of the largest proportion possible of the radiated thermal output into the preforms.
As an alternative to this, the application DE 10 2006 015853 A1 suggests that the preforms are heated in individual irradiation chambers, which in each case enclose the preforms circumferentially, wherein the individual chambers are arranged in the form of a carousel. Here, each preform is heated both by the internal wall of the chamber which is formed as a ceramic infrared radiator and also by a rod-shaped infrared radiator, which is introduced into the preform. As can be taken from a schematic illustration in DE 10 2006 015853 A1, the preform here is completely introduced into the irradiation chamber. However, it remains unresolved as to how the temperature distribution in the individual chambers can be influenced flexibly and as independently as possible from one another, and how the thermal output irradiated into the chamber can be utilised as effectively as possible for heating the preform.
Although the heating chambers in DE 10 2006 015853 A1 are mainly thermally insulated radially towards the outside, they are in direct contact with one another so that heat interchange between the heating chambers is possible. In addition, the chambers are open at the top so that heat can escape uncontrollably and unused. It is however desirable to generate different circumferential and radial temperature profiles controllably and energy efficiently in the heating elements. In this respect there is therefore a requirement for an improved single-chamber furnace.
In an embodiment, the present invention provides a rotary furnace for conditioning preforms that includes a heating wheel and a plurality of heating modules, each for heating a preform, that are disposed on the heating wheel. Each heating module includes a heating chamber, a holding device for holding the preform and a lifting device. The heating device includes at least one heating radiator adapted for irradiating an outer wall section of the preform with infrared radiation, a recess for introducing the preform, and walls having an insulating layer configured to thermally insulate the heating chamber. The lifting device is configured to raise and lower at least one of the holding device and the heating chamber so as to move the preform into or out of the heating chamber.
Exemplary embodiments of the invention are described in more detail below with reference to the drawings, in which:
a and 3b show schematic longitudinal sections through variants of the heating chamber;
a and 6b show schematic longitudinal sections through alternative embodiments of the heating chamber according to the invention with a cooling function for the outer wall of the heated preform;
In an embodiment, the present invention provides a furnace in which the heating chambers can be adapted in the most flexible manner possible and independently of one another to a desired temperature profile of the preforms, both in the circumferential and in the axial directions, and in which heat losses are minimised.
Due to the fact that, in embodiments of the present invention, the walls of the heating chamber, in particular a bottom wall of the heating chamber oppositely situated to a recess for introducing the perform and a side wall bordering the bottom wall of the heating chamber, comprise an insulating layer, the circumferential and axial heating profiles of the individual heating chambers can be flexibly adapted to the respective requirement independently of one another. In addition heating losses are reduced.
Materials suitable for the insulating layer are preferably plastics, in particular PET, polyethylene, polystyrene, Neopor or polyurethane, but also aluminium, in particular composite aluminium, ceramics, mineral fibres such as glass or rock wool, ceramic film as composites with other materials, wood or cork. Other conceivable materials would be cellulose composite systems, hemp, flax, coconut or reed panels. Mineral foams such as foam mortar, pumice stone, perlite, swelling clay, expanded mica, calcium silicate or foamed glass can also be used. Composites comprising any selection of the mentioned materials would also be conceivable.
Preferably a lid is provided on the recess of the heating chamber in order to close the heating chamber to insulate it thermally in the uncharged state. In this way the temperature variations in the heating chamber are minimised and thermal losses further reduced.
In an embodiment the holding device comprises at least one gripper element, which can be cooled by a liquid and/or air stream, for holding and cooling a mouth region of the preform during irradiation. In this way it can be ensured that the mouth region, which should remain unchanged during the blow moulding process, is not inadmissibly heated, so that adequate stability of the mouth region during the irradiation and the subsequent blow moulding process is ensured.
Preferably at least one ventilation inlet is provided on the holding device for blowing in cooling air eccentrically into the preform in order to pass the blown-in cooling air essentially on the inner side of the preform wall. In this way the situation can be avoided in that the inner side of the preform heats up disproportionately in comparison to a central wall section or to the outer side of the preform.
In an embodiment at least one ventilation inlet on the heating chamber for introducing a cooling air flow and one ventilation outlet for discharging the air flow are provided in order to pass cooling air along the outer side of the preform wall. In this way the situation can be avoided in that the outer side of the preform heats up disproportionately in comparison to a central wall section or to the inner side of the preform.
Preferably the heating chamber and the holding device are pivotably supported with respect to one another in order to swirl the cooling air flow in the heating chamber and/or to pass it along the preform in a helical manner. In this way the surface of the preform can be uniformly cooled circumferentially.
In an embodiment at least one temperature probe is provided in the heating chamber for determining an inner temperature, whereby the furnace further comprises a control unit for adjusting an infrared heating power and/or a cooling air flow in the heating chamber based on the determined inner temperature. In this way a chronological progression of the heating of the preform is adjusted in the heating chamber and/or a certain temperature level is maintained in the heating chamber.
An embodiment of the invention furthermore comprises air baffle devices, which are tilted towards a direction of rotation of the heating wheel and/or are curved in order to pass air, which is built up by the rotation of the heating wheel, against the heating chambers. In this way a cooling air flow can be realised without the use of an additional blower. The path of the air flow can also be controlled by specific shaping of the air baffle devices.
Preferably the heating chamber comprises at least one heating radiator in the form of a heating coil embedded in a ceramic layer, whereby the ceramic layer is adapted for an emission in the range from 2 to 3.5 μm. Due to the ceramic layer a radiating surface which is larger and more uniform in comparison to the heating coil can be provided and the spectral range of the radiated heat radiation and its spatial distribution can be adapted to produce a desired temperature distribution in the preform. In the wavelength range from 2 to 3.5 μm a particularly greater proportion of the incident heat radiation is absorbed in the preform so that the heating can be concentrated very well onto a certain wall section.
In a particularly embodiment the heating chamber comprises at least one heating radiator in the form of a bright (high intensity/point source) radiator with a radiation maximum at a wavelength of less than 2 μm, especially a brightly emitting halogen radiator, a brightly emitting light-emitting diode and/or a brightly emitting laser. Due to less inertia, radiators of this nature can be particularly precisely controlled with respect to time and facilitate adaptation of the irradiation spectrum to various preform materials and material thickness values. Due to the comparatively low absorption in the wall of the preform, the bright radiation can excite a passive radiator arranged on the rear side of the irradiated wall.
Preferably the heating modules furthermore each comprise a heating rod for irradiating an inner wall section of the preform with infrared radiation, whereby the device is furthermore adapted for raising and lowering the holding device and/or the heating rod, in order to introduce the heating rod into the preform or to withdraw the heating rod from it. With the additional heating rod the wall of the preform can be irradiated and heated particularly uniformly over its whole thickness. Additionally, in this way wall sections can be irradiated, in particular in the vicinity of the mouth region of the preform, which can only be inadequately irradiated by the outer heat radiator. The lifting device also simplifies the axial profiling of the preform by targeted irradiation of axial sections of the preform.
In an embodiment the heating modules also comprise a thermally insulating housing for the heating rod, in which the heating rod can be withdrawn whereby in particular a lid is provided on the housing in order to close the housing, providing thermal insulation when the heating rod is withdrawn. In this way heating losses can be minimised when the heating rod is withdrawn. In addition, it is possible to reduce temperature variations of the heating rod.
Preferably, several radiators are provided in the longitudinal direction on the heating rod with different and/or separately adjustable heating power. Thus, axial thermal profiling of the preform wall, in particular on its inner side, can be facilitated by selective activation of the individual radiators. Additionally, time-variation of the axial profiling is possible without moving the heating rod in the preform.
Preferably, at least one ceramic layer for the radiation of infrared light is provided on the heating rod, in particular for the conversion of bright radiation with a radiation maximum at a wavelength of less than 2 μm to a longer wavelength radiation with a wavelength in the range of 2 to 3.5 μm. In this way it is possible to operate the heating rod completely or partially passively in that incident bright radiation from the outer side of the preform passes through its wall onto the heating rod where it is converted into a radiation which is particularly effective for heating the inner side of the preform.
In an embodiment a radiation shield, which can be cooled by a liquid and/or air flow is provided on the heating rod and/or on the holding device in order to shield and/or cool the mouth section against the infrared radiation emitted by the heating rod. In this way excessive heating of the mouth region is prevented, in particular in order to ensure stable holding of the preform in the heating chamber and for a stable shape of the mouth region during the blow-moulding process.
In another embodiment the heating chambers are thermally insulated from one another.
In a further embodiment the heating chambers are only thermally insulated towards the outside and are in thermally interchanging contact with one another.
In a further embodiment the mouth regions of the preforms are directly cooled with an air flow. This air flow can be formed by a blower inside or outside the furnace and can pass through pipes to the areas to be cooled.
In a further embodiment the heating chambers are each cooled by a separate blower.
In an alternative embodiment the preforms are accommodated in the heating chamber without being suspended and instead stand in the perpendicular direction with the mouth region facing downwards.
As can be seen from
As illustrated in
Furthermore, in the heating chamber 4 at least one heating element 11 is provided for the irradiation of the outer side 5a of the preform 5.
a and 3b show different variants of the heating elements 11 and 15, which can be combined together as required depending on the embodiment. For the sake of clarity the insulating layer 10 is only indicated.
In
On the heating rod 13 of
With the variant in
In
a and 3b show the shielding element 17 with which the mouth region 5c of the preform 5 is protected against excessive irradiation. At the places where no heating radiator 11 is provided the inner side of the heating chamber 4b, 4c is preferably provided with a coating 19 which reflects the heat radiation.
The heating radiators 11 and 15 could also radiate electromagnetic radiation in a different wavelength range, for example microwave radiation, as an alternative to infrared radiation. Furthermore, the radiators are not restricted to the illustrated rotationally symmetrical shapes. In particular, various radiators 11, 15 can also be formed just as circumferential segments, for example annular segments for the circumferentially selective profiling of the preforms 5, i.e. so-called preferential heating.
Preferably, a layer 19, which reflects infrared radiation, is provided on the inner side of the housing 23 and the lids 21 and 25. The lids 21 and 25 could be implemented as one part and, for example, for closing the heating chamber 4 or the housing 23 by pivoting in front of them. They can however also be implemented as several parts and, for example as indicated in
With closures of this nature for the heating chambers 4 and the housings 23 heating of the chambers 4 or the heating rods 13 after the furnace 1 is switched on could be speeded up to achieve the operating temperature.
In
A base plate of the heating chamber 4 for a supporting ring 5e formed on the preform 5 can be formed as a cooled protective shield 29, whereby the gripper 27 could be brought into thermally conducting contact (not illustrated) with the protective shield 29 in order to cool the gripper 27 with the aid of the protective shield 29. In addition the gripper 27 can be formed such that it is in thermally conducting contact with the sleeve-like shielding element 17, so that both the gripper 27 and the shielding element 17 can be cooled with the aid of the cooling shield 29. This is particularly advantageous for reducing the number of feed lines for the cooling liquid and/or cooling air.
a and 6b show variants of the heating chamber 4 with active cooling of the outer side 5a of the preform 5 by introducing a cooling air flow 14, symbolised in each case by arrows.
In the variant of
In the variant of
With the arrangement illustrated in
With the aid of temperature probes 41 the temperature in the heating chambers 4, in particular after closing the lid 21 with the heating chamber 4 uncharged, can be set to a constant value or to a uniform output temperature for heating the preforms 5.
The features of the described embodiments and variants can be combined as required. In particular different variants of the irradiation, insulation and cooling can be combined.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
Number | Date | Country | Kind |
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10 2009 047 540.0 | Dec 2009 | DE | national |
This application is a U.S. National Phase application under 35 U.S.C. §371 of International Application No. PCT/EP2010/006421, filed on Oct. 20, 2010, and claims benefit to German Patent Application No. DE 10 2009 047 540.0, filed on Dec. 4, 2009. The International Application was published in German on Jun. 9, 2011 as WO 2011/066885 A2 under PCT Article 21 (2).
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2010/006421 | 10/20/2010 | WO | 00 | 7/10/2012 |