Godet Rolls

Tokuden rolls can be used for a variety of purposes requiring precise temperature control. These include, but are not limited to synthetic fibers including BCF fibers, carbon fibers, and spandex. They are also useful for laminating, for use as godets, for films, nonwovens, and a variety of other purposes.

There are two principals that ensure perfect heat distribution and performance, induction heating and the jacket chambers:

Induction heating is essentially a method by which the shell heats itself. By supplying an alternating current to the induction coil (inner cylinder), a magnetic field around the coil is produced. This generates an induced current inside the roll shell (outer cylinder). This creates resistance heat which heats the roll.

The jacket chamber is an important part of the success of the Tokuden rolls. Inside the rolls are long, thin gun drilled holes called jacket chambers. These chambers are set parallel to the roll axis. A thermal medium is vacuum sealed in each chamber. This medium constantly repeats cycles of vaporization and condensation. The jacket chambers absorb and disperse the heat energy generated inside the shell roll (heat pipe effect) effectively transmitting the heat uniformly to the roll surface.

There are several advantages to using Tokuden Induction Heated rolls: 

• Wide temperature range - Due to the efficiency of induction heating, this system can provide high temperatures and precise control in 1°C increments from 40°C to 420°C.
• Uniform surface temperature - The heat pipe effect maintains a uniform temperature both across and around the roll. The temperature profile stays uniform even when a thermal load is applied.
• Compact, easy to use electrical system - Since the jacket rolls use electricity, there is no need for additional facilities or special construction. The equipment takes up minimal space and is easy to operate.
• Energy efficient and green - The low maintenance rolls are very energy efficient compared to other methods, such as oil or steam heating. In these times of high energy costs, the Tokuden rolls can bring about a substantial cost savings. There are also no dirty, messy materials such as oil that can make for an unclean and unsafe work environment.

Mist Hybrid Roll

The Mist Cooled Hybrid Roll uses a special misting system that injects a fine mist of water in the chamber between the coil and the roll shell. The vaporization of the mist transports the thermal energy out of the roll. The primary concept is that a compressed air/mist nozzle is designed on the end of the coil support rod. The mist passes through the coil support rod, passes between the coil and the roll shell, passes out of the coil support rod on the far side and is discharged. Tokuden can also design this system with a discharge hose on the same side as the air/mist nozzle for rolls that are cantilevered or otherwise cannot have opposite side discharge.

The main advantages of this design are: 

1. Means of heating the unit and the means of cooling the unit are independent. The minimum time lost from heating to cooled roll is realized.
2. Mist input and output is without rotary joint.
3. Simple design that uses a small quantity of water.
4. Appropriate mist conditions can be controlled by the roll surface temperature sensor and the rotary transformer.
5. The reduction in cooling time is dramatic.

Utility Power Super Steamer

Tokuden also has in its product line a superheated steam generator called the Utility Power Super Steamer (UPSS), which uses components of Tokuden's core technology to make super-heated steam with minimum energy.

The UPSS can heat both water and the saturated steam found at many manufacturing sites. The special transformer design allows for the heating of the steam up to 700°C and higher. This is much hotter than can be achieved by other means. It is done by using a special transformer that has a Y shaped wound magnetic core with a three phase coil in a triangular configuration. The arrangement allows electrical balance and efficient use of power. The process to heat the water is simple. The water (or saturated steam) enters the primary conductor tube and circulates around the metal core and continues on to circulate the second and then third magnetic core. It then circulates a second time through the secondary conductor tubes and exits as superheated steam. There are five key benefits to the design of the UPSS.

1. You can achieve very high temperature (700°C and up)
2. Low Energy Costs - because you are using a transformer instead of a frequency inverter, there are significant savings.
3. Achieved heating effiency is 95% or better.
4. The system is clean/green.
5. Low maintenance - periodic tube cleaning and valve replacement.