Patent Application
20110290409
The present disclosure is generally related to a jacketing apparatus and more particularly is related to a method and system for forming an extruded jacket over elongated objects.
The process of extruding a jacket using a crosshead die has been in practice for many years. It has proved successful in many applications where a jacket is needed to cover an object. Commonly, a jacketing material is heated and extruded through a crosshead die where it takes the shape of the crosshead die. When the jacketing material exits the crosshead die, it hardens and must be applied to an object within a short period of time, thus constraining a jacketing process to a relatively quick time table. Additionally, conventional jacketing process requires various sized parts, such as die heads, for different sizes of the object to be jacketed. This can add significant cost and time to a jacketing process, as various components of a jacketing machine must be changed frequently.
Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.
Embodiments of the present disclosure provide a system and method for forming an extruded jacket over an elongated object. Briefly described, in architecture, one embodiment of the system, among others, can be implemented as follows. A quantity of heated jacketing material is provided. At least one die has an entry side and an exit side, the entry side proximate to the quantity of heated jacketing material, wherein the quantity of heated jacketing material is extruded through the at least one die. A heating device is located proximate to the exit side of the at least one die, wherein the heating device positioned to maintain the extruded quantity of heated jacketing material in a heated state. A wrapping device is positioned to rotate the elongated object, wherein the extruded quantity of heated jacketing material is wrapped around at least a portion of the elongated object.
The present disclosure can also be viewed as providing methods for forming an extruded jacket over an elongated object. In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: heating a quantity of jacketing material; extruding the heated quantity of jacketing material through at least one die; maintaining the extruded, heated quantity of jacketing material in a heated state; and wrapping the extruded, heated quantity of jacketing material around at least a portion of an outer surface of the elongated object, wherein the extruded, heated quantity of jacketing material substantially surrounds an exterior surface of the elongated object.
Another embodiment of a method for forming an extruded jacket over an elongated object, among others, can be broadly summarized by the following steps: extruding a substantially uniform sheet of heated jacketing material through a sheet die; maintaining the extruded jacketing material in a heated state within an oven, wherein the oven is positioned to substantially surround an exit point of the sheet die and a section of the elongated object positioned proximate to the exit point of the sheet die; helically wrapping the extruded jacketing material about the elongated object; and cooling the wrapped elongated object.
Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.
Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
The system 10 may be employed in a variety of industries that require jacketed objects, such as jacketed pipes or jacketed cables. Presently, jacketing an object using an extruded jacketing material may be completed with a crosshead die. Although this technique has proved successful for many years, it has inherent shortcomings. These include inherent structural limitations, including the need for interchanging various equipment and tooling parts. For example, as the size of the objects that require jacketing increases, a greater variety of equipment and tooling devices are needed, since specifically sized equipment and tooling devices are required for specifically sized objects. The present disclosure may allow for objects of various sizes to be jacketed without the need for replacement of equipment and tooling device.
The system 10 includes an elongated object 20 that is in a position to be jacketed by the system 10. The elongated object 20 may include object that requires jacketing, or benefit from jacketing. An object with a jacket coating may be protected from, or less susceptible to damage, wear and tear, or harmful environments. For example, in many industrial settings, various pipes, conduits, and cables are needed to transport products or energy from one location to another. Some of these pipes, conduits, or cables may be open to the elements such that they are subject to inclement weather, or being contacted from tools, machinery, or other items. If the pipe, conduit, or cable is damaged, it may be expensive and time consuming to make necessary repairs, which may require significant down time of the facility where the pipe, conduit, or cable is used. The system 10 may allow for these pipes, conduits, and cables, as well as other elongated objects, to be jacketed and protected from damage.
As is shown in
The quantity of heated jacketing material 30 may be heated to a temperature that is dependent on the type of jacketing material used. The heated jacketing material 30 will be at a temperature that results in the heated jacketing material being a substantially molten consistency, soft enough to be malleable, but hard enough to take a given shape. This may include a substantially molten consistency that allows the quantity of heated jacketing material 30 to be extruded into a substantially flat sheet. The jacketing material 30 may be provided to the die 40 in a variety of ways, such as with a system of pipes, as is shown in
The jacketing material 30 may be heated prior to it being molded through the die 40, which may occur at any point prior to it being molded through the die 40. For example, the jacketing material 30 may be first heated, and then pumped to the die 40. Other configurations are also possible. For example, the die 40 may include a heating section that pre-heats the jacketing material 30 prior to entering the die 40. The jacketing material 30 may be heated to a consistency where it is capable of being submitted to the die 40, it can successfully pass through the die 40, and where it can retain the shape of the die 40 after it exits the die 40. For example, the jacketing material 30 may have a molten consistency when it is heated before entry to the die 40. When it is passed through the die 40, the jacketing material 40 may be cooled slightly to the point where the jacketing material 30 holds the shape of the die 40.
Naturally, different types of jacketing materials 30 may require different heating temperatures, all of which are considered within the scope of the present disclosure. Furthermore, as will be discussed herein, the rate of jacketing (i.e., the rate of movement between the components of the system 10 and the elongated object 20) may also dictate the temperature of the jacketing material 30. The jacketing material 30 may be heated to the point where it is malleable, or substantially molten. At this consistency, the jacketing material 30 may be malleable enough to be processed through the die 40, yet resistant enough to hold the shape that the die 40 gives it.
The die 40 has an entry side 42 and an exit side 44, which may generally oppose each other, but may also be in a configuration where the entry side 42 and the exit side 44 are not in direct, or substantial opposition. In accordance with this disclosure, the entry side 42 of the die 40 is the side or sides of the die 40 that receives the heated jacketing material 30, whereas the exit side 44 of the die 40 is the side or sides of the die 40 that emits the extruded jacketing material 30 into the heating device 50. The operation of an extrusion process with a die 40 is well known in the art, and therefore further discussion herein is not warranted.
The die 40 may have a die cutter or other extrusion-cutting device that is shaped to extrude the heated jacketing material 40 with a specific shape. Any type of die cutter shape may be used with the system 10. Most commonly, the die cutter may be configured to extrude the heated jacketing material 30 into a substantially flat, ribbon of jacketing material 32. In accordance with this disclosure, the ribbon of jacketing material 32 may be characterized as any portion of the extruded jacketing material 30 that is emitted from the die 40. The die 40 may provide the ribbon of jacketing material 32 with a substantially planar, elongated shape. This substantially uniform, flat, ribbon-like shape allows the ribbon of jacketing material 32 to be properly wrapped around the elongated object 20, such that it covers all intended surfaces of the elongated object 20. Other shapes of the ribbon of jacketing material 32 may also be used. This may include ribbon shapes with specific textures, such as raised ridges, raised edges, etc., all of which are considered within the scope of the present disclosure. For example, when the ribbon of jacketing material 32 is slightly overlapped, it may be desirable for it to be substantially flat, but have a transitioned thickness across the width of the ribbon of jacketing material 32.
When the ribbon of jacketing material 32 exits the die 40, it will still have a residual heated temperature from the pre-heated jacketing material 30. However, without further heating, the ribbon of jacketing material 32 is susceptible to hardening, deforming, or otherwise degrading in quality, which is likely to affect the quality of the jacketing on the elongated object 20. Accordingly, the system 10 includes a heating device 50 located proximate to the exit side 44 of the die 40. The heating device 50 provides a heated atmosphere to the ribbon of jacketing material 32, thereby preventing it from hardening into an unworkable state with the jacketing operation. In other words, the heating device 50 maintains the ribbon of jacketing material 32 in a heated state.
The heating device 50 may include many types of heating elements, heating environments, or heat-providing systems. For example, as is shown in
As one can see, it may be beneficial for the heating device 50 to be as enclosed as possible, to prevent heat dissipation and conserve energy, however, the heating device 50 may require various inlet and outlet ports to allow for the elongated object 20 to be inserted in, and exit from the enclosure. The inlet and outlet ports may be sized to closely fit the elongated object 20 with or without the ribbon of jacketing material 32 applied thereto. A sealing structure, constructed from rubber, plastic, or another material may be placed proximate to the inlet and outlet ports to prevent a substantial loss of heat from the inlet and outlet ports. Other configurations of heating devices 50 may also be used with the system 10. These may include heating devices 50 without enclosures, such as with heated-air that is directed towards the ribbon of jacketing material 32. Variations with the heating device 50 may be dependent on the type of jacketing material 30 used, and its properties.
A wrapping device 60 is positioned to rotate the elongated object 20 while the ribbon of jacketing material 32 is being applied. The wrapping device 60 may be a two-axis motion control device capable of rotating the elongated object 20 about an axis. As is shown in
The system 10 may be best described with respect to coordinates x, y, and z, as shown in
It is noted that the heating device 50 moves latterly about the elongated object 20 because the exit area of the ribbon of jacketing material 32 from the die 40 is within or proximate to the heating device 50. Thus, the ribbon of jacketing material 32 exiting the die 40 is moved along the elongated object 20, so the ribbon of jacking material 32 can be wrapped around the elongated object 20. As one can see, the rotation of the elongated object 20, the movement of the heating device 50 (and exit point of the ribbon of jacketing material 32 from the die 40), and the extrusion of the ribbon of jacketing material 32 from the die 40 may all need to occur in cooperation in order to successfully wrap the ribbon of jacketing material 32 about the elongated object 20. In other words, if one of the variable movements is too great or not great enough, the ribbon of jacketing material 32 may not be properly applied. For example, if the rotation of the elongated object 20 is too slow, then gaps between the wrapped ribbon of jacketing material 32 may occur. If the rotation of the elongated object 20 is too great, then substantially overlapping of the wrapped ribbon of jacketing material 32 may occur.
Thus, the various movements of the components of the system 10 may be relative. For example, the lateral movement of the heating device 50 may depend on the rotation of the wrapping device 60. If the wrapping device 60 moves slowly, then the heating device 50 will have a slow lateral movement to allow for proper covering of the elongated object 20 with the ribbon of jacketing material 32. The movement of the components of the system 10 may also vary depending on the size of either the elongated object 20, and/or the width of the ribbon of jacketing material 32. For example, if the width of the ribbon of jacketing material 32 is four inches, then the heating device 50 may move laterally at four inches per each rotation of the rotating device 60, assuming no overlap of the ribbon of jacketing material is needed. The interactions of the components of the system 10 to successfully jacket the elongated object 20 will be discussed further with respect to
As is shown in
To aid in ensuring that the individual wrappings of the ribbon of jacketing material 32 form a unitary jacketed surface 34, a pressure application device 70 may be used to apply pressure to the ribbon of jacketing material 32 around the elongated object 20. The pressure application device 70 may include any device capable of applying a quantity of pressure to the ribbon of jacketing material 32, such as a roller biased with a spring. The positioning of the pressure application device 70 may vary, depending on the design of the system 10 and/or the need for pressure application. For example, the pressure application device 70 may be positioned to apply pressure to a seam 36 between two sections of the ribbon of jacketing material 32 applied to the elongated object 20. This may help ensure that the two sections properly fuse together, thereby eliminating the seams 36. Additionally, any number of pressure application devices 70 may be used to ensure that the jacketed surface 34 forms properly.
The system 10 may also include other components to aid in forming an extruded jacket over the elongated object 20. For example, the system 10 may include one or a plurality of temperature sensors 56 to monitor the temperature proximate to the heating device 50, and/or within the heating enclosure 52. The temperature sensor 56 may pair with an adjustable airflow mechanism 54, which may circulate air within the heating enclosure 52. Proper air circulation within the heating enclosure 52 may maintain a uniform temperature within the heating enclosure 52, which maintain the ribbon of jacketing material 32 at a uniform temperature. Maintaining the ribbon of jacketing material 32 at a substantially uniform temperature, from when it exits the die 40, to when it is fully in place around the elongated object 20, may ensure that the jacketed surface 34 is of sufficient quality, and won't be susceptible to unwanted imperfections.
Once the elongated object 20 with the jacketed surface 34 has cooled sufficiently, it may be used within a variety of industries and operations. Since many industries require various sizes, and types of elongated objects 20 and jacketed surfaces 34 covering those elongated objects 20, the system 10 may be fully adjustable and customizable to be successful in any industry or use. For example, the system 10 may jacket an elongated object 20 having a 1-inch diameter and/or an elongated object 20 having a 16-inch diameter with the same components, since the system 10 would not require a re-tooling or exchanging of parts, but only a slight adjustment of the system variables, i.e., the rate of rotation of the elongated object 20, the rate of lateral movement of the heating device 50, and the extrusion rate of the ribbon of jacketing material 32. This ability to quickly adjust the system 10 for use with a variety of elongated objects may eliminate the need for high-cost equipment conversion and set up tools.
While the wrapping of the ribbon of jacketing material 32 is occurring, the pressure application device 70 is positioned to apply pressure to an area near where the ribbon of jacketing material 32 first contacts the elongated object 20. Although placement of the pressure application device 70 may vary, it may be most preferable for pressure to be applied very close to the initial formation of a seam 36 between sections of the ribbon of jacketing material 32, to ensure that the seam 36 is properly fused as the ribbon of jacketing material 32 cools. However, other placements of the pressure application device 70 may also be beneficial. For example, a pressure application device 70 may be located within an inlet or outlet port (not shown) of the heating enclosure 52, which may apply pressure to the fusing seam 36, but may also be used to interface the rotational movement of the elongated object 20 with the non-rotational movement of the heating enclosure 52.
Formation of a seam 36 between individual layers of the ribbon of jacketing material 32 may vary. For example, as is depicted in
As can be seen, ribbons of the jacketing material 32 with varying widths may be used to jacket various elongated objects 20. In many cases, the larger diameter of the elongated object 20, the larger the width of the ribbon of jacketing material 32 may be. Likewise, the smaller the diameter of the elongated object 20, the smaller the width of the ribbon of jacketing material 32 may be. To convert the system 10 from one width of the ribbon of jacketing material 32 to another, a system operator may simply need to replace one die 40 with another. It is noted that the width of the ribbon of jacketing material 32 may depend on the material used for jacketing. Some materials may permit larger widths, whereas other materials may require smaller widths for proper jacketing. Other considerations for the width of the ribbon of jacketing material 32 may also be present, all of which are considered within the scope of the present disclosure.
The system 110 includes a quantity of heated jacketing material 130, which is positioned proximate to the elongated object 120. The quantity of heated jacketing material 130 may be formed from any material and may be made from solid pellets of jacketing material that are heated to form a malleable material having a substantially molten consistency capable of being extruded. The heated jacketing material 130 may include a variety of materials, including polymeric materials, polyvinyl materials, urethanes, 2-part polyethylene materials, other forms of vinyl, or any combination thereof. Other types of heated jacketing materials 130 may also be used, as one having ordinary skill in the art would recognize. The quantity of heated jacketing material 130 may be heated to a temperature that is dependent on the type of jacketing material used. The heated jacketing material 130 will be at a temperature that results in the heated jacketing material being a substantially molten consistency, soft enough to be malleable, but hard enough to take a given shape. This may include a substantially molten consistency that allows the quantity of heated jacketing material 130 to be extruded into a substantially flat sheet.
Once the quantity of heated jacketing material 130 is sufficiently heated, it is transported to at least one die 140. The quantity of heated jacketing material 130 may be transported via any method or device, such as a rotatable corkscrew shaft 133 powered by a motor 135, as illustrated in
Directly abutting the exit side of the die 140 is a heating device 150, which may be a substantially enclosed, heated atmosphere, and referred to as such. The heated atmosphere 150 may be any type of oven or heated enclosure, heated by any type of heating device and including any type of additional heating components, such as circulating fans 154. The heated atmosphere 150 may have an adjustable air flow provided at a predetermined flow rate to maintain a uniform temperature within the heated atmosphere 150. The heated atmosphere 150 may have any temperature that is sufficient to keep the flat sheet of jacketing material 132 at a usable temperature and molten state for jacketing the elongated object 120. The ribbon of jacketing material 132 exits the die 140 into the heated atmosphere 150, which retains the ribbon of jacketing material 132 at a usable temperature. The usable temperature is any temperature wherein the ribbon of jacketing material 132 can be wrapped around the exterior of the elongated object 120.
As is illustrated in
Once the ribbon of jacketing material 132 is within the heated atmosphere 150, it is positioned proximate to the elongated object 120. The elongated object 120 may be rotated about an elongate axis within the heated atmosphere 150 with a series of movement mechanisms 180, such as control-activated rollers. The elongated object 120 may be moved laterally along an axis parallel to the elongated length of the elongated object 120 within the heated atmosphere 150. Similarly, elongated object 120 may remain stationary and the ribbon of jacketing material 132 may be moved laterally along an axis of the elongated object 120. As the elongated object 120 is rotated, the ribbon of jacketing material 132 contacts an exterior surface of the elongated object 120. The continual rotation and lateral movement between the elongated object 120 and the ribbon of jacketing material 132, in combination with the continual contact of the ribbon of jacketing material 132 results in a jacketing surface 134 being formed on the elongated object 120.
A winding apparatus (not shown) may be used to wrap the ribbon of jacketing material 132, similar to what was described with respect to the first exemplary embodiments. The jacketing surface 134 is wrapped around the exterior surface of the elongated object 120 and substantially surrounds the elongated object 120. The jacketing surface 134 may be wrapped in a helical fashion to form a uniform, smooth protective covering for the elongated object 120. A support structure 182 may support the elongated object 120 with the jacketing surface 134 as it moves through the heated atmosphere 50. The support surface may also act as a pressure applicator to the jacketing surface 134, which may help seal any seams between individual pieces of the ribbon of jacketing material 132.
The jacketing surface 134 on the elongated object 120 may fully surround the elongated object 120 and may be virtually seamless, as the jacketing surface 134 fuses together to surround the elongated object 120 without seams. However, the surrounding jacketing surface 134 may also have a seam 136, or sealed edge seam between various portions of the jacketing surface 134, especially when it is still within the heated atmosphere 150. In accordance with this disclosure, any covering of the elongated object 120 with the jacketing surface 134 may or may not include a seam 136 within the jacketing surface 134. Once the jacketing surface 134 is wrapped around the exterior surface of the elongated object 120, the heated atmosphere 150 may keep the elongated object 120 with jacketing surface 134 at a heated temperature for any period of time. The elongated object 120 with jacketing surface 134 may then be cooled within the heated atmosphere 150 or outside of the heated atmosphere 150.
Once the elongated object 120 with jacketing surface 134 has cooled sufficiently, it may be used within a variety of industries and operations. The system 110 may be fully adjustable and customizable to be successful in any industry or use. For example, the angle of wrapping, the width of the ribbon of jacketing material 134, the size or design of the die 140, the rate of lateral movement of the elongated object 120, or any other feature of the jacketing apparatus may be adjusted as needed. The system 110 may be compatible with, and used successfully with any size of elongated object 120 without needing to change the components of the system 110. For example, the system 110 may jacket an elongated object 120 having a 1-inch diameter and an elongated object 120 having a 16-inch diameter with the same components. This may eliminate the need for high-cost equipment conversion and set up tools.
As is shown at block 202, a quantity of jacketing material 30 may be heated. The heated quantity of jacketing material 30 may be extruded through at least one die 40 (block 204). The extruded, heated quantity of jacketing material 32 may be maintained in a heated state (block 206). The extruded, heated quantity of jacketing material 32 may be wrapped around at least a portion of an outer surface of the elongated object 20, wherein the extruded, heated quantity of jacketing material 32 substantially surrounds an exterior surface of the elongated object 20 (block 208).
May additional steps or processes may be included with the method, as well as many variations to the presently described method steps. For example, the extruded, heated quantity of jacketing material 32 may be maintained in a heated state by placing it in a substantially enclosed heated atmosphere proximate to an exit side 42 of the at least one die 40. Thus, the quantity of jacketing material 30 exits the at least one die 40 into the heated, enclosed atmosphere. To wrap the quantity of jacketing material 32, referred to as the ribbon of jacketing material 32, the elongated object 20 may be rotated within the substantially enclosed, heated atmosphere, as is described with respect to
Additionally, steps may also be used to ensure that the jacket surface 34 applied to the elongated object 20 is suitable to withstand the elongated object's 20 intended use. For example, the heated quantity of jacketing material 30 and/or the ribbon of jacketing material 32 may need to be maintained at a substantially uniform temperate during the jacketing process. Additionally, once the ribbon of jacketing material 32 is applied, pressure may need to be applied to a seam 36 between at least two sections of ribbon of jacketing material 32 around the elongated object 20. To cure the ribbon of jacketing material 32 into the jacketed surface 34, the sections of wrapped ribbons of jacketing material 32 may need to be cooled, thereby eliminating the seam 36.
Depending on various aspects of the jacketing process, the method may require determining at least one of an angle of the wrapping the ribbon of jacketing material 32 around at least a portion of an outer surface of the elongated object 20, a width of the ribbon of jacketing material 32, and a lateral movement of the heating device 50 about a length of the elongated object 20 as a function of a size of the elongated object 20. The size of the elongated object 20 may include a diameter of the elongated object 20 and/or a length of the elongated object 20. Any additional steps or processes not explicitly recited herein may also be used with the method, all of which are considered within the scope of the present disclosure.
As is shown at block 302, a substantially uniform sheet of heated jacketing material may be extruded through a sheet die. The extruded jacketing material may be maintained in a heated state within an oven, wherein the oven is positioned to substantially surround an exit point of the sheet die and a section of the elongated object positioned proximate to the exit point of the sheet die (block 304). The extruded jacketing material may be helically wrapped about the elongated object (block 306). The wrapped elongated object may be cooled (block 308). Additional steps may include rotating the elongated object about an elongated axis of the elongated object and laterally moving the sheet die and oven along the elongated axis of the elongated object.
It should be emphasized that the above-described embodiments of the present disclosure, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims.
This application claims benefit of U.S. Provisional Application Ser. No. 61/349,436, entitled, “Method and System for Forming an Extruded Jacket over Elongated Objects,” filed, May 28, 2010, the entire disclosure of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61349436 | May 2010 | US |
