Extruded product, extrusion device and extrusion method

Abstract

An extruded product is provided. The extruded product includes: a first side having a first recess pattern defined by a first rotating die during an extrusion process; and a second side portion having a second recess pattern defined during the extrusion process, the second side portion being opposite the first side portion. The extruded product further includes at least one overlap region for which a total depth of the first and second recessed patterns exceeds a maximum thickness of the extruded product.

Description

Technical Field

[0001] This invention relates to a method for producing extruded products, an extrusion apparatus, and extruded products. Background Technology

[0002] Extrusion is an industrial manufacturing process used to manufacture products. In traditional extrusion, product material is pushed through a static die, and the cross-section of the resulting product corresponds to the cross-section of the die.

[0003] Another method has been developed to allow for the production of more complex products via extrusion. The applicant has made a significant contribution to a technique known as 3D extrusion, in which at least one rotary die is used to define the final dimensions of the product. The rotary die may be configured with a surface pattern that is transferred to the surface of the product during production. Depending on the surface pattern, this achieves different cross-sections of the final product.

[0004] 3D extrusion is performed by pushing or pulling product material through a static passage, thereby shaping the product material into a main profile. Immediately downstream of the passage, the main profile enters a channel at least partially defined by the outer surface of a rotary die. As it passes through the channel, the main profile is shaped to define the final shape of the final product. The rotary die allows the final shaping to include patterning on the surface of the final product.

[0005] As 3D extrusion gains considerable market interest, there is a need to implement this technology in products that have so far been too complex for extrusion processes. For example, advanced morphologies are achieved only through extensive post-processing, which is expensive and disadvantageous for various reasons.

[0006] Therefore, there is a need for an improved manufacturing method that provides a more universal approach to the production of advanced products. Summary of the Invention

[0007] The object of this invention is to overcome, at least in part, one or more of the limitations of the prior art described above. In particular, the object is to provide an extruded product having an increased surface area to allow for its use in high-tech applications.

[0008] The present invention aims to provide an apparatus and method for producing extruded products having an overlapping configuration, and to provide the extruded product itself. In the context of this specification, the term "overlapping configuration" is used to define a cross-section in which the surface region of the upper side of the extruded product extends beyond the surface region of the bottom side of the extruded profile.

[0009] To address these objectives, an extruded product or extruded profile is provided. The extruded product includes: a first side having a first recessed pattern defined by a first rotary die during the extrusion process; and a second side having a second recessed pattern opposite to the first side, wherein the extruded product further includes at least one overlapping region, with respect to the overlapping region, the total depth of the first and second recessed patterns exceeding the maximum thickness of the extruded product.

[0010] The advantage of extruded products is that complex surface patterns, especially those with increased surface area, are produced in a single process without requiring extensive post-processing.

[0011] At at least one overlapping area, the depth of the first recessed pattern and / or the depth of the second recessed pattern may exceed half the maximum thickness of the extruded product.

[0012] The first recessed pattern may be arranged away from the second recessed pattern in the length and / or width direction of the extruded product.

[0013] The minimum distance between the first recessed pattern and the second recessed pattern can define the minimum material thickness of the extruded product, wherein, in at least one overlapping region, the minimum material thickness is less than half of the maximum thickness of the extruded product.

[0014] The first recessed pattern and / or the second recessed pattern may be repeated.

[0015] The first recessed pattern and / or the second recessed pattern may have varying extensions along the length of the extruded product.

[0016] The first recessed pattern and / or the second recessed pattern may have varying extensions in the width direction of the extruded product.

[0017] The second recessed pattern can be defined by a second rotating die during the extrusion process, or by a static die during the extrusion process.

[0018] According to a second aspect, an extrusion apparatus is provided. The extrusion apparatus includes: a static passage configured to form a product material into a main profile; and a channel disposed immediately downstream of the passage. The channel is defined by the outer surface of a first rotary die and the outer surface of a second die disposed opposite to the first rotary die, thereby forming a channel height between the first die and the second die, wherein the first rotary die includes a first morphological pattern, and the second die includes a second morphological pattern, and wherein the total height of the first morphological pattern and the second morphological pattern exceeds the channel height.

[0019] The second mold can be a static mold or a rotary mold.

[0020] The first rotary mold can be synchronized with the second rotary mold.

[0021] The circumference of the first rotary die and / or the second rotary die can be equal to the length of the resulting extruded product.

[0022] The circumference of the first rotary die and / or the second rotary die may differ from the length of the resulting extruded product.

[0023] The channel may have a longitudinal extension along the production direction, and the rotation axis of each of the first and second rotary dies may be arranged at an angle relative to the production direction. Preferably, the rotary dies may be arranged at an angle of 90°±25° relative to the production direction.

[0024] The channel may be defined by a bottom region, an upper region and two opposing side regions, which together form a closed space, wherein at least a portion of the two opposing regions may be formed by the lateral surface regions of the first and second rotating molds.

[0025] At least a portion of at least one additional region may be defined by the lateral surface region of another rotating mold.

[0026] At least one of the bottom region, the upper region, and the two opposing side regions may be defined by a static support surface.

[0027] The morphological pattern may include at least one protrusion configured to form a separation notch in the extruded product and / or a significant local reduction in the thickness of the extruded product.

[0028] A significant reduction in the thickness of extruded products can limit the removable portion of the extruded product.

[0029] At least one protrusion may extend over the entire width of the first rotary mold and / or the second rotary mold, or over a portion of the width of the first rotary mold and / or the second rotary mold.

[0030] The protrusion can extend along the width of the rotating mold in a linear or curved manner.

[0031] The extrusion apparatus may also include an inlet configured to add additional material to the product material.

[0032] The inlet for adding additional material can be located upstream of the first mold and the second mold, at the first mold and the second mold, or downstream of the first mold and the second mold.

[0033] The inlet can be configured to allow the addition of other materials, which may be liquid or solid materials in powder or granular form.

[0034] The extrusion apparatus may also include an adjustment mechanism configured to adjust the position of the first die and / or the second die, thereby adjusting the size of the channel.

[0035] The extrusion apparatus may also include at least one die core located in the channel, the die core forming a hollow portion of the extruded product.

[0036] According to a third aspect, an extrusion method is provided. The extrusion method includes: i) shaping material by extruding or pulling product material through a channel of an extrusion die, the channel being at least partially defined by lateral surface regions of at least a first rotary die and a second die arranged opposite to the first rotary die; ii) providing a first recessed pattern defined by the first rotary die to a first side of the product material; and iii) providing a second recessed pattern defined by the second die to a second side of the product material, wherein the total depth of the first and second recessed patterns exceeds the maximum thickness of the extruded product.

[0037] Other objects, features, aspects and advantages of the invention will become apparent from the following detailed description and from the accompanying drawings.

[0038] This specification uses certain terms, which are defined as follows.

[0039] Extrusion: The process of forcing material under pressure through a profile forming tool (also called a die) with holes that define the cross-section and appearance of the output material.

[0040] Pultrusion: The process of pulling material under pressure through a profile forming tool (also called a die) with holes that define the cross-section and appearance of the output material.

[0041] Dynamic extrusion: The process of extruding material under pressure through a tool with a rotational forming component (die) that can impart a variety of cross-sections and / or appearances to the material, such as patterns on one or more surfaces, as well as dimensional variations in cross-sectional area and / or material thickness.

[0042] Dynamic pultrusion: The process of pulling material under pressure through a tool with a rotational forming member (die) that can give the material a variety of cross-sections and / or appearances, such as patterns on one or more surfaces, as well as dimensional variations in cross-sectional area and / or material thickness.

[0043] Mold: This is usually the name used by professionals for profile forming tools.

[0044] Rotary die: The rotating profile forming part of a tool used for dynamic extrusion / pultrusion.

[0045] Support surface: The surface of the smallest cross-section of the extrusion die through which the extruded material is forced under pressure, and thus forms the surface that ultimately defines the cross-section and appearance of the shaped material.

[0046] Static support surface: A rigid support surface over which the extruded material is forced to pass relative to its discharge velocity. Because the rigid support surface is static, a velocity difference exists between the static support surface and the extruded material, resulting in friction and heat. By adjusting the length of the support surface, the total amount of friction can be adjusted, and thus the discharge pressure, balance, and velocity can be regulated.

[0047] Rotary support surfaces: Rotary support surfaces are the surfaces of a rotating die that define the cross-section of the material being molded, thus allowing for patterning and variations in material thickness. Rotary support surfaces typically generate significantly less resistance and friction to the flowing material compared to static support surfaces, which have previously been a major problem due to imbalances between different portions of the cross-section of the material being molded. Static support surfaces are defined by all support surfaces throughout the die. This often leads to process failure during startup.

[0048] Pre-support (surface): The surface area that the extruded material passes through just before it enters the rotary die and its rotary support surface. Pre-support significantly reduces the cross-sectional area of ​​the material, so that the subsequent rotary die does not have to bear unnecessarily large forces from the forming material. Pre-support, combined with upstream material forming, plays a central role in controlling and / or regulating the material flow through the die.

[0049] Dynamic extrusion and dynamic pultrusion: processes that shape (ceramic) materials using rotating dies integrated into an extrusion die. The extrusion die has one or more rotating dies. The cross-sectional profile of the material to be shaped may optionally be defined upstream of where the material to be shaped reaches the rotating die. The outer circumference of the rotating die, i.e., the lateral surface region, defines a rotating support surface, which, together with other rotating support surfaces and / or static support surfaces in the die, ultimately defines the appearance and cross-section of the material to be shaped.

[0050] Pattern: Any structural configuration that can be transferred from the die to the extruded material. A pattern can be macroscopic (visible to the human eye) or microscopic. A pattern can extend across the entire molding material or only over a very small portion of it. Typically, although not required, a pattern is a morphological configuration. Examples of patterns included in the context of this specification are variations in the thickness of the molding material, reinforcing ribs, channels, and macroscopic and microscopic structures. Even perfectly smooth surfaces are considered to define patterns herein. Attached Figure Description

[0051] Embodiments of the invention will now be described by way of example with reference to the accompanying schematic diagrams, in which:

[0052] Figure 1 It is a top view of a series of extruded products based on the example.

[0053] Figure 2a It is a cross-sectional view of the extrusion apparatus based on the example.

[0054] Figure 2b This is a cross-sectional view of an extrusion apparatus based on another example.

[0055] Figure 3 It is a cross-sectional view based on a schematic arrangement of a rotating die in an example extrusion apparatus.

[0056] Figure 4a It is a cross-sectional view of the extruded product based on the example.

[0057] Figure 4b This is a cross-sectional view of an extruded product based on another example.

[0058] Figure 4c This is an isometric view of the extruded product based on the example.

[0059] Figure 5 This is an isometric view of the components of the extrusion apparatus based on the example.

[0060] Figure 6a This is an isometric view of the extruded product based on the example.

[0061] Figure 6b yes Figure 6a The cross-sectional view of the extruded product is shown.

[0062] Figure 7 It is based on the example extrusion apparatus and the equidistant cross-sectional view of the resulting extruded profile.

[0063] Figure 8 This is an isometric view of the extrusion apparatus based on the example.

[0064] Figure 9 It is a cross-sectional view of the extrusion apparatus based on the example.

[0065] Figure 10 This is a diagram illustrating the method used in the example. Detailed Implementation

[0066] from Figure 1 The extruded product 100 is shown at the beginning. The extruded product 100 is in the form of an extended profile, which is continuously produced by an extrusion apparatus and / or by an extrusion method, as will be further described below.

[0067] The extruded product 100 can be produced as a linear array of continuous product segments 110. The product segments 110 are preferably connected to each other, but can be easily separated to form individual extruded products.

[0068] The extruded product 100 includes an upper side portion 112 and a bottom side portion 114 (not shown). The upper side portion 112 forms a first side portion having a first recessed pattern 120. The first recessed pattern 120 is defined by a first rotary die during the extrusion process. The bottom side portion forms a second side portion having a second recessed pattern 130 (not shown). The second side portion 114 is opposite to the first side portion 112. The extruded product 100 also includes at least one overlapping region 140, with respect to which the total depth of the first recessed pattern 120 and the second recessed pattern 130 exceeds the maximum thickness of the extruded product 100.

[0069] exist Figure 2a and Figure 2b The image shows an extrusion apparatus 1 for producing extruded profiles 100. From... Figure 2a Beginning with Figure 2, the extrusion unit 1 is configured to process (i.e., shape) any suitable material along the production direction PD. This material is preferably a malleable material and / or a viscoelastic material and / or a malleable material with elastic properties and / or a viscoplastic material with elastic properties.

[0070] The material can be designed to have a preferred strength of 0.06 Ω / cm. 2 Or the resistivity in the following range.

[0071] The material can also be designed to have a strength of at least 10 m·kg·s -3 ·K -1 Thermal conductivity.

[0072] In a preferred example, the material is a composite material. This example can be achieved by adding graphite to a composite material, for example, the material having a graphite content of at least 50% by weight, such as 60% by weight or more.

[0073] Another preferred example could be aluminum.

[0074] The device 1 includes a first rotating mold 3 extending in the radial direction R and the width direction X. The first rotating mold 3 has two opposing first sidewalls and second sidewalls, and an outer peripheral (lateral) surface region 4 extending in the width direction X between the sidewalls. The rotating mold 3 has a cylindrical shape.

[0075] The apparatus 1 also includes a material defining region 7, which has a longitudinal direction Y aligned with the production direction PD, a height direction Z, and a width direction X perpendicular to the height direction Z. The material defining region 7 includes a channel 10. Figure 2a In the device 1 shown, the passage 9 is preceding the channel 10 (on the production direction PD).

[0076] The passage 9 is defined circumferentially by one or more walls 11 to form a closed circumference for the ceramic material. A channel 10, located immediately downstream of the passage 9, is defined at least partially by the lateral surface region 4 of the rotating mold 3. The channel 10 is also defined by opposing supports 14 arranged opposite to the rotating mold 3, and opposing first and second channel portion sidewalls extending between the rotating mold 3 and the opposing supports 14.

[0077] In the example shown, the opposing support 14 is formed by the circumferential (lateral) surface region 6 of the second rotating mold 5, which also extends in the radial direction R and the width direction X, and has two opposing first sidewalls and second sidewalls at each side of the outer circumferential (lateral) surface region 6. The second rotating mold 5 also has the shape of a cylindrical member.

[0078] The first rotary mold 3 and the second rotary mold 5 are capable of rotating about corresponding axes that extend transversely to the production direction PD, and are arranged to allow the lateral surface regions 4 and 6 to apply pressure to the surface of the material as the material is fed through the material-limiting region 7 while the rotary molds 3 and 5 are rotating.

[0079] according to Figure 2a In the embodiment shown, passage 9 is configured to deform the material at a predetermined supply rate into a main profile 36 having a maximum height H1 and a first maximum height D1 when the material leaves passage 9, wherein the predetermined supply rate depends on the material.

[0080] Channel 10 is configured to apply increased pressure to the main profile 36 via rotary dies 3 and 5, further deforming the material into a final shape 37 with a minimum height H2. For this purpose, the first rotary die 3 is configured to be at a minimum distance D2 from the opposing support 14, i.e., the second rotary die 5, depending on the maximum permissible pressure applied by the rotary dies 3 and 5 at this minimum distance D2. The maximum permissible pressure corresponds to the maximum height difference between the main profile 36 and the final profile 37, and depends on the specific topographic patterns on the lateral surface regions 4 and 6 of the rotary dies 3 and 5.

[0081] The maximum permissible pressure also depends on the viscoelasticity and viscoplasticity of the material, and therefore on the difference between the final height H3 of the molded material due to the elasticity of the material and the height H2 immediately following the channel 10.

[0082] According to one example, a passage 9 is formed between at least two sidewalls 11; that is, between a top pre-support and an opposing bottom pre-support, wherein the top pre-support is arranged above the opposing bottom pre-support in the height direction Z. The top pre-support and / or the bottom pre-support may include a wake element.

[0083] Typically, the wake element protrudes in the direction from the sidewall into passage 9. According to one example, the wake element protrudes in the height direction from the sidewall into passage 9. The wake element can be designed based on the material's elasticity to provide the correct height of the main profile as it enters passage 10. Here, elasticity refers to the material's expansion after being extruded in passage 9. As the material passes through the wake element, it creates a wave pattern within the material.

[0084] One advantage of device 1 is that the maximum load is controlled in both passage 9 and channel 10, which allows the extrusion device 1 to be designed according to the material to be processed and the desired processing speed. Controlling the maximum load according to the material to be processed achieves productivity with high-quality output and reduces the risk of breakage, for example, due to excessive stress on the material.

[0085] according to Figure 2a In the example shown, the extrusion device 1 receives material; the material is shaped into the form of a main profile 36 in passage 9, and then the material is directly shaped into the form of a final product 37 in passage 10. Figure 2a It is also shown that the final product 37 has a height H1 that is smaller than the height H2 of the main profile 36 due to the further pressure on the main profile 36 in the channel 10. Figure 2a It is also shown that if molding is carried out at elevated temperatures, the molded material can have a height H3 that is smaller than the height H1 of the final profile 36 due to shrinkage during cooling from the final profile 37.

[0086] like Figure 2a As further shown, the extrusion apparatus 1 may include a pulling and stretching device 54 disposed downstream of the channel 10 and configured to pull the material along the production direction PD as the material leaves the channel 10. One advantage is that the pulling and stretching device 54 can dynamically stretch the material during molding, for example, to obtain an equidistant pattern in the production direction PD of the molded material. The pulling and stretching device 54 can also be used to guide the molded material in the width and / or height directions.

[0087] The pulling and stretching device 54 can be any type of device, including means for gripping the molding material and means for pulling. According to one example, the pulling and stretching device 54 includes a control device 55 for controlling the pulling force applied to the molding material. The control device 55 may include a sensor 56 and / or may be connected to a sensor 56 for monitoring the state of the molding material. The sensor includes means for sending analog and / or digital information to the control device. This information relates to the state of the molding material, and the control device 55 is configured to process information for controlling the pulling and stretching device.

[0088] Figure 2a An initial region A is also shown, in which material is squeezed into passage 9 by means of a device (not shown) that applies external pressure in the production direction PD, i.e., material is extruded, and / or material is dragged through passage 9 by means of a device (not shown) that drags material in the production direction PD, i.e., pultruded material.

[0089] Region A of the extrusion device 1 includes a funnel-shaped opening 43, in which the material changes from an initial form having a cross-section larger than that of the passage 9. However, the shape of the opening can vary depending on the type of material, the temperature, and the device used to extrude the material.

[0090] Region B is arranged directly after region A, wherein region B corresponds to the longitudinal extension of passage 9, and the main profile 36 is formed at region B due to the material changing caused by the pressure applied to the material from the side wall 11 of passage 9 when the material moves through passage 9.

[0091] Region C is arranged directly after region B, wherein region C corresponds to the longitudinal extension of channel 10, and the final profile 36 is formed at region C due to the material change caused by the pressure applied to the material from at least the rotating mold 3 of channel 10 and the opposing support 14 (i.e. the second rotating mold 5).

[0092] Zone D is located directly after Zone C, corresponding to the section of the production line after channel 10, and wherein the material may optionally begin to cool (in the case of an extrusion process using elevated temperatures). In this case, the final profile 36 begins to change due to shrinkage caused by the temperature drop. It should be noted that shrinkage may also occur due to the drying of the formed material. In Zone D, the final profile 37 can undergo various production measures such as cooling, heating, stretching, and compression to achieve the desired properties of the formed material, thereby changing the final profile 37 into a desired shape with the desired material properties.

[0093] In a preferred embodiment, the final profile 36 is cooled relatively quickly immediately after extrusion. This rapid cooling may take place, for example, in region D, preferably between 0 cm and 100 cm from the end of region C, or within a few seconds after extrusion.

[0094] Rapid cooling can be performed by quenching, even using water, air, or any other suitable medium to achieve a rapid decrease in temperature, and optionally also to obtain specific material properties of the final profile 36. Quenching can be advantageous, especially for plastic or polymer materials, to quickly fix the geometry of the final profile 36.

[0095] For aluminum, rapid cooling, for example through quenching, will provide increased strength properties.

[0096] The length of region D typically depends on the material properties and the working environment surrounding the material in region D. Material properties include, for example, heat dissipation characteristics and the mass properties of the material being cooled. For example, a thinner material cools faster than a thicker material. The working environment refers to, for example, ambient temperature and humidity. For example, a hotter environment slows down the cooling process compared to a colder environment.

[0097] Zone E is located directly after Zone D, and Zone E corresponds to the following section of the production line in which the material has been dried or cooled to a predetermined temperature, representing the final molding temperature of the molding material, and in which no or only infinitesimal molding variations will continue. The height H3 of the molding material in Zone E may optionally be less than the height H2 of the final profile 37.

[0098] It should be noted that for some materials, the extrusion unit 1 can operate at room temperature, thus requiring little or no cooling. In this embodiment, regions D and E will be very short if both are necessary.

[0099] Reference Figure 2a The extrusion apparatus shown and further described below includes a first rotary die 3 comprising a first morphological pattern and a second rotary die 5 comprising a second morphological pattern. The total height of the first and second morphological patterns exceeds the channel height D2.

[0100] Now go to Figure 2b This shows another example of the extrusion device 1. Figure 2b The extrusion device 1 and Figure 2b The extrusion device 1 has many similarities, and these common features will not be repeated. However, in Figure 2bIn this configuration, the extrusion device 1 does not have a second rotating die. Instead, the channel 10, located immediately downstream of the passage 9, is at least partially defined by the lateral surface region 4 of the rotating die 3 and a static opposing support 14 arranged opposite to the rotating die 3. Therefore, the channel height D2 is defined as the minimum distance between the lateral surface region 4 of the rotating die 3 and the static opposing support 14.

[0101] exist Figure 2b In the example shown, the rotary mold 3 includes a first topographic pattern, and the opposing support 14 includes a second topographic pattern. The total height of the first and second topographic patterns exceeds the channel height D2.

[0102] Based on the various examples given in this article, and as... Figure 3 As illustrated schematically and generally, the extruded profile 100 has a first side 112 and a second side 114. The first side 112 has a first recessed pattern 120 defined by a first rotary die 3 during the extrusion process, and the second side 114 has a second recessed pattern 130 opposite to the first side 112. The extruded product 100 also includes at least one overlapping region 140, where the total depth of the first recessed pattern 120 and the second recessed pattern 130 exceeds the maximum thickness T of the extruded product 100.

[0103] These features of the extruded product 100 are made possible by means of the extrusion apparatus 1. The product forming channel 10 is defined by the outer surface 4 of the first rotary die 3 and the outer surface 6 of the second rotary die 5 arranged opposite to the first rotary die 3, thereby forming a channel height D2 between the first die 3 and the second die 5. The first rotary die 3 includes a first morphological pattern 60 having a first height X1, and the second die 5 includes a second morphological pattern 70 having a second height X2, wherein the total height X1 + X2 of the first morphological pattern 60 and the second morphological pattern 70 exceeds the channel height D2.

[0104] It should be noted that the second rotating mold 5 can be replaced by the static opposing support member 14, as described above. Figure 2b As described. In this case, the opposing support 14 includes a second topographic pattern 70 with a second height X2, wherein the total height X1 + X2 of the first topographic pattern 60 and the second topographic pattern 70 exceeds the channel height D2.

[0105] An example of the overlapping region 140 of the extruded product 100 in Figure 4a and Figure 4b As shown in the diagram, the first recessed pattern 120 is formed with a depth Y1, and the second recessed pattern 130 is formed with a depth Y2. Figure 4aIn the example shown, depth Y1 is greater than half the maximum thickness T of the extruded product 100, such that Y1 > T / 2. Similarly, depth Y2 is greater than half the maximum thickness T of the extruded product 100, such that Y2 > T / 2. Specifically, in the example shown, Y1 = Y2. At the overlapping region 140, the total depth Y1 + Y2 of the first recessed pattern 120 and the second recessed pattern 130 exceeds the maximum thickness T of the extruded product 100.

[0106] exist Figure 4b In the example shown, depth Y1 is greater than half the maximum thickness T of the extruded product 100, such that Y1 > T / 2. However, depth Y2 is less than half the maximum thickness T of the extruded product 100, such that Y2 < T / 2. Therefore, in the example shown, Y1 ≠ Y2. At the overlapping region 140, the total depth Y1 + Y2 of the first recessed pattern 120 and the second recessed pattern 130 still exceeds the maximum thickness T of the extruded product 100.

[0107] exist Figure 4c Another example of an extruded profile 100 is shown in the figure. The overlapping region 140 extends over all or at least most of the extruded profile 100. The first recessed pattern 120 and the second recessed pattern 130 extend along the longitudinal direction of the extruded profile 100, that is, along a direction parallel to the production direction PD.

[0108] exist Figure 5 The image shows another example of an extruded profile 100 exiting a channel 10 formed between two opposing rotary dies 3 and 5. The rotary dies 3 and 5 are provided with corresponding morphological patterns 60 and 70. These patterns 60 and 70 are wavy structures, thereby forming corresponding recessed patterns 120 and 130 in the extruded product 100. Therefore, in this example, the recessed patterns 120 and 130 extend in both the longitudinal and transverse directions.

[0109] At the overlapping region 140, i.e., the region where recessed patterns 120 and 130 are provided on the two sides of the extruded product 100, the total depth of the first recessed pattern 120 and the second recessed pattern 130 exceeds the maximum thickness of the extruded product 100.

[0110] Figure 6a and Figure 6b An extruded profile 100 according to an example is shown. The extruded profile 100 has hollow edge structures 150, and overlapping regions 140 extend laterally between the edge structures 150. At the overlapping regions 140, recessed patterns 120, 130 overlap each other in the thickness direction such that the total depth of the first recessed pattern 120 and the second recessed pattern 130 exceeds the maximum thickness of the extruded product 100.

[0111] exist Figure 7Another example of the extrusion apparatus 1 and the resulting extruded profile 100 is shown in the figure. The extrusion apparatus 1 includes, as already referred to, Figure 2a and Figure 2b The described passage 9, and the downstream passage 10 formed between the two rotary dies 3, 5. Each rotary die 3, 5 is provided with a morphological pattern 60, 70 in the form of a hexagonal shape, thereby forming an overlapping region 140 in the extruded product 100 (extending substantially over the entire extruded profile 100), at the overlapping region 140, where the total depth of the resulting first recessed pattern 120 and the resulting second recessed pattern 130 exceeds the maximum thickness of the extruded product 100.

[0112] exist Figure 8 Another example of the extrusion apparatus 1 is shown in the figure. One or more static regions of the channel 10, i.e., the side regions and the alternatively opposing support 14, are here replaced by one or more additional rotating dies.

[0113] Figure 8 A rotary mold assembly comprising four rotary molds is schematically shown. Channel 10 is defined here by a first rotary mold 3, a second rotary mold 5 arranged opposite to the first rotary mold 3 and forming an opposing support 14, a third rotary mold 34 replacing one of the side regions, and a fourth rotary mold 35 arranged opposite to the third rotary mold 34.

[0114] Figure 8 This is merely an example. Channel 10 can be defined by one or more rotary dies 3, 5, 34, 35. For example, channel 10 can be defined by two rotary dies 3, 5, 34, 35, while the remaining areas defining channel 10 are static. As another example, channel 10 does not need to have a rectangular cross-section; channel 10 can be defined by three regions forming a triangular cross-section, six regions forming a hexagonal cross-section, etc. One or more regions, possibly all regions, of channel 10 can be defined by specific rotary dies 3, 5, 34, 35. Each of the rotary dies 3, 5, 34, 35 can have a specific topographic pattern on its lateral surface area for imprinting the sides of the molding material using a corresponding recessed pattern.

[0115] The second rotary die 5, the third rotary die 34, and / or the fourth rotary die 35 may be arranged in a manner similar to that of the first rotary die 3 described above, to produce the same or different recessed patterns on both sides of the extruded product 100. The second rotary die 5, the third rotary die 34, and / or the fourth rotary die 35 may include annular recesses and / or flange portions, which may be arranged to mate with the annular recesses and / or flange portions of the first rotary die 3.

[0116] One or more of the rotary dies 3, 5, 34, and 35 can be driven. According to one example, two or more rotary dies 3, 5, 34, and 35 are synchronized. This has the advantage of feeding material through channel 10 at the same speed. However, asynchronous rotary dies 3, 5, 34, and 35 can also be used to create friction and / or special indentation patterns and / or compensate for material differences.

[0117] The extrusion device 1 can be arranged with a combination of textured and non-textured rotary dies 3, 5, 34, and 35, as long as they form an overlapping area 140 as described above.

[0118] Figure 9 A schematic cross-sectional side view of an extrusion device 1 comprising two opposing rotating dies 3 and 5 is shown. Figure 9 The extrusion apparatus 1 is further shown to include a passage 9 and a second passage 46, the second passage 46 being connected to a profile defining region 7 upstream of the passage 10 for supplying additional material to the passage 10, thereby utilizing the material from the passage 9 to form a layered extruded product 100. Figure 9 The extrusion apparatus 1 is also shown to include a third passage 47 for supplying a third material to the profile-defined region 7.

[0119] According to one example, the third passage 47 is an extrusion or pultrusion passage, which is similar to passage 9 arranged to process the material. According to one example, passage 47 is a passage configured as a conveyor unit for transporting material to the profile-defined region 7. Although in Figure 9 Not shown, but the second rotating mold 5 is provided with a topographic pattern to form an overlapping area as described above.

[0120] Now go to Figure 10 The extrusion method 200 is schematically illustrated. The extrusion method includes shaping material 202 by squeezing or pulling product material through a channel in an extrusion die, the channel being at least partially defined by lateral surface regions of at least a first rotary die and a second die arranged opposite to the first rotary die. The extrusion method also includes providing a first recessed pattern 204 defined by the first rotary die for a first side of the product material, and a second recessed pattern 206 defined by the second die for a second side of the product material. The total depth of the first and second recessed patterns exceeds the maximum thickness of the extruded product.

[0121] Finally, some general notes will be given regarding the extruded product 100, the extrusion apparatus 1, and the extrusion method 200. These notes generally apply individually or in any combination to all the examples described herein.

[0122] Starting from the overlapping region 140, the overlapping region 140 may extend over the entire extruded product 100 or over a portion of the extruded product 100.

[0123] The morphological patterns 60 and 70 of the extrusion device 1 and the resulting recessed patterns 120 and 130 of the extruded product 100 can be continuous or sequential. Patterns 60 and 70 can extend centrally in the dies 3 and 5, and they can extend longitudinally, laterally, or in any combination such as diagonally, zig-zac, front-to-back zig-zag, or spirally. Patterns 60 and 70 can be in the form of beaded edges, raised areas, grids, etc., and the resulting recessed patterns 120 and 130 can form structures to facilitate knocking, punching, or other forms of separation.

[0124] The extruded product 100 may include one or more overlapping regions 140, which form an increased surface area, improved wettability, reduced resistance, or improved electrochemical properties.

[0125] The recessed patterns 120 and 130 can be on a micro or macro scale. The recessed patterns 120 and 130 can be symmetrical, or they can be designed to produce varying thicknesses in the extruded profile 100.

[0126] Extruded product 100 can withstand post-processing such as heating, curing, and exposure to UV radiation.

[0127] The extruded product 100 can be designed such that the overlapping area 140 provides improvements for various product functions such as structural spring elements, deformation control, thermal behavior, acoustic properties, increased surface area for photovoltaic applications, hydrodynamics, photochemical properties, grids, attachment points, weld joints, adhesion, etc.

[0128] Extruded product 100 can be used in a wide variety of applications such as household appliances, heat exchangers, coolers, beams, bumpers, walls, sound-absorbing panels, automobiles, batteries, anodes and cathodes, separators, flow battery modules, electrolytes, fuel cells, solar panels, lighting fixtures, sandwich elements, drainage devices, degassing devices, and slip protection devices. In a specific example, the extruded product is a bipolar plate for a fuel cell. It can also be a plate for a hydrolyzer.

[0129] As can be seen from the above description, although various embodiments of the present invention have been described and illustrated, the present invention is not limited thereto, but may be practiced in other ways within the scope of the subject matter defined in the appended claims.

Claims

1. An extruded product, comprising: A first side portion, the first side portion having a first recessed pattern defined by a first rotating die during extrusion, and A second side portion, having a second recessed pattern defined simultaneously with the first recessed pattern during the extrusion process, the second side portion being opposite to the first side portion. The extruded product further includes at least one overlapping region, wherein the total depth of the first recessed pattern and the second recessed pattern in the at least one overlapping region exceeds the maximum thickness of the extruded product.

2. The extruded product according to claim 1, wherein, At at least one overlapping region, the depth of the first recessed pattern and / or the depth of the second recessed pattern exceeds half of the maximum thickness of the extruded product.

3. The extruded product according to claim 1 or 2, wherein, The first recessed pattern is arranged away from the second recessed pattern in the length and / or width direction of the extruded product.

4. The extruded product according to claim 3, wherein, The minimum distance between the first recessed pattern and the second recessed pattern defines the minimum material thickness of the extruded product, wherein, at the at least one overlapping region, the minimum material thickness is less than half the maximum thickness of the extruded product.

5. The extruded product according to any one of the preceding claims, wherein, The first recessed pattern and / or the second recessed pattern are repeating.

6. The extruded product according to any one of the preceding claims, wherein, The first recessed pattern and / or the second recessed pattern have varying extensions along the length of the extruded product.

7. The extruded product according to any one of the preceding claims, wherein, The first recessed pattern and / or the second recessed pattern have varying extensions in the width direction of the extruded product.

8. The extruded product according to any one of the preceding claims, wherein, The second recessed pattern is defined by a second rotating die during the extrusion process.

9. The extruded product according to any one of the preceding claims, wherein, The second recessed pattern is defined by a static die during the extrusion process.

10. The extruded product according to any one of the preceding claims, wherein, The at least one overlapping region is configured to provide increased surface area, improved wettability, reduced resistance, and / or improved electrochemical properties.

11. The extruded product according to any one of the preceding claims, wherein, The at least one overlapping region is configured to provide structural spring elements, equal grid structures, attachment or welded joints, and / or improved deformation control, thermal behavior, acoustic properties, hydrodynamics, photochemical properties, and / or adhesion.

12. The extruded product according to any one of the preceding claims, wherein, The extruded products form part of heat exchangers, coolers, beams, bumpers, walls, sound-absorbing panels, automotive products, batteries, anodes, cathodes, separators, flow battery modules, electrolytes, fuel cells, solar panels, sandwich elements, drainage devices, degassing devices, and / or slip protection devices.

13. The extruded product according to any one of the preceding claims, wherein, The surface resistivity is 0.06 Ω / cm 2 Or smaller.

14. The extruded product according to any one of the preceding claims, wherein, The thermal conductivity of the extruded product is at least 10 m·kg·s. -3 ·K -1 .

15. The extruded product according to any one of the preceding claims, wherein, The extruded product is made at least in part of a polymer, plastic and / or metal, and preferably the extruded product is made at least in part of a composite material.

16. The extruded product according to claim 15, wherein, The material of the extruded product includes graphite, preferably 50% by weight or more.

17. An extrusion apparatus, comprising: A static pathway, wherein the static pathway is configured to form the product material into a main profile, and The channel, which is arranged immediately downstream of the passage, The channel is defined by the outer surface of a first rotating mold and the outer surface of a second mold arranged opposite to the first rotating mold, thereby forming a channel height between the first mold and the second mold. The first rotating mold includes a first topographic pattern, and the second mold includes a second topographic pattern. The total height of the first morphological pattern and the second morphological pattern exceeds the channel height.

18. The extrusion apparatus according to claim 17, wherein, The second mold is a static mold.

19. The extrusion apparatus according to claim 17, wherein, The second mold is a rotary mold.

20. The extrusion apparatus according to claim 19, wherein, The first rotating mold is synchronized with the second rotating mold.

21. The extrusion apparatus according to claim 19 or 20, wherein, The circumference of the first rotary die and / or the second rotary die is equal to the length of the resulting extruded product.

22. The extrusion apparatus according to claim 19 or 20, wherein, The circumference of the first rotary die and / or the second rotary die is different from the length of the resulting extruded product.

23. The extrusion apparatus according to any one of claims 19 to 22, wherein, The channel has a longitudinal extension along the production direction, and wherein the rotation axis of each of the first rotary mold and the second rotary mold is arranged at an angle relative to the production direction, preferably, the rotary mold is arranged at an angle of 90°±25° relative to the production direction.

24. The extrusion apparatus according to any one of claims 17 to 23, wherein, At least the first rotating mold has a radially protruding flange at each longitudinal end.

25. The extrusion apparatus according to any one of claims 19 to 24, wherein, The channel is defined by a bottom region, an upper region, and two opposing side regions, the bottom region, the upper region, and the two opposing side regions together defining the dimensions of the channel, wherein at least a portion of the two opposing regions is formed by the lateral surface regions of the first rotating mold and the second rotating mold.

26. The extrusion apparatus according to claim 25, wherein, At least a portion of at least one additional region is defined by a lateral surface region of another rotating mold.

27. The extrusion apparatus according to claim 25 or 26, wherein, At least one of the bottom region, the upper region, and the two opposing side regions is defined by a static support surface.

28. The extrusion apparatus according to any one of claims 19 to 27, wherein, The morphological pattern includes at least one protrusion configured to form a separation notch in the extruded product and / or a significant local reduction in the thickness of the extruded product.

29. The extrusion apparatus according to claim 28, wherein, The significant reduction in the thickness of the extruded product defines the removable portion of the extruded product.

30. The extrusion apparatus according to claim 28 or 29, wherein, The at least one protrusion extends over the entire width of the first rotary mold and / or the second rotary mold, or over a portion of the width of the first rotary mold and / or the second rotary mold.

31. The extrusion apparatus according to any one of claims 28 to 30, wherein, The protrusion extends along the width of the rotating mold in a linear or curved manner.

32. The extrusion apparatus according to any one of the preceding claims further includes an inlet configured to add additional material to the product material.

33. The extrusion apparatus according to claim 32, wherein, The inlet for adding additional material is located upstream of the first mold and the second mold, at the first mold and the second mold, or downstream of the first mold and the second mold.

34. The extrusion apparatus according to claim 32 or 33, wherein, The inlet is configured to add additional materials, which are either liquid or solid materials in powder or granular form.

35. The extrusion apparatus according to any one of claims 17 to 34, further comprising an adjustment mechanism configured to adjust the position of the first die and / or the second die, thereby adjusting the size of the channel.

36. The extrusion apparatus according to any one of claims 17 to 35, further comprising at least one die core located in the channel, the die core forming a hollow portion of the extruded product.

37. An extrusion method, comprising: Material is shaped by extruding or pulling it through a channel in an extrusion die, the channel being at least partially defined by the lateral surface regions of at least a first rotating die and a second die arranged opposite to the first rotating die. A first recessed pattern defined by the first rotary die is provided on the first side of the product material. A second recessed pattern defined by the second mold is provided on the second side of the product material, the second recessed pattern being provided simultaneously with the first recessed pattern. The total depth of the first recessed pattern and the second recessed pattern exceeds the maximum thickness of the extruded product.

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