Co-extrusion Preformer with Monolithic Through Stiffener
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Solution Overview
Problem
Existing co-extrusion methods for complex profiled elements require complex, heavy, and costly tooling that is cumbersome and energy-intensive, necessitating lengthy and expensive machining for geometry changes.
Innovation Solution
A preformer design with superimposed channels and integral stiffeners that allow elastomer mixes to flow around the stiffener, reducing pressure requirements and enabling additive manufacturing for rapid, cost-effective production and easy modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional heavy tooling is used to withstand high pressures, then the structural strength is sufficient, but the weight and complexity of the preformer increase
Solution Approach 1:
The patent changes the structural parameters by introducing a monolithic through stiffener that extends through the entire preformer height, transforming the load-bearing mechanism from distributed heavy walls to a concentrated central reinforcement structure, thereby reducing overall weight while maintaining strength
Solution Approach 2:
The stiffener extends in the vertical dimension through the entire preformer, creating a three-dimensional load distribution network that provides structural strength without requiring heavier horizontal wall sections, thus reducing weight while maintaining pressure withstanding capability
2Manufacturing precision
If electroerosion machining is used to produce complex preformer geometries, then manufacturing precision is achieved, but production time and cost increase
Solution Approach 1:
The patent merges the stiffener with the partition walls into a single monolithic structure, allowing both components to be manufactured as one integrated piece using additive manufacturing, thereby eliminating sequential machining operations and reducing production time while maintaining geometric precision
Solution Approach 2:
The patent replaces traditional mechanical electroerosion machining with additive manufacturing technology, which builds complex geometries layer by layer, significantly reducing manufacturing time while achieving the required precision for co-extrusion tooling
3Use of energy by moving object
If channel cross-section is reduced to lower pressure requirements, then energy consumption decreases, but flow capacity and production rate are limited
Solution Approach 1:
The patent segments the single channel flow into multiple parallel channels, each with optimized cross-section, allowing the elastomer mix to be distributed across several flow paths that collectively maintain high flow capacity while each individual channel operates at lower pressure requirements
Solution Approach 2:
The patent utilizes the vertical dimension by stacking channels in multiple levels with the stiffener extending through all levels, enabling parallel flow paths that increase total flow capacity without increasing the horizontal footprint or pressure requirements of individual channels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a compact, lightweight, and energy-efficient co-extrusion tooling that reduces energy consumption and manufacturing costs, allowing for rapid iteration and production of complex profiled elements with minimal tooling changes.
Implementation Method 1
a leading edge which allows the elastomer mix following the second channel, to pass around the said stiffener by dividing up into two sub-flows
Data Source
AI summary
A preformer (1) is designed to extrude jointly a plurality of elastomer mixes in a direction of flow (X1), in order to form a profiled element, the preformer comprising for this purpose, superimposed in a direction of stacking (Z1), transverse to the direction of flow (X1), a first channel (11), a second channel (12) which is separated from the first channel (11) by a first partition (15), then a third channel (13), separated from the second channel (12) by a second partition (16), the preformer also comprising a stiffener (20) formed integrally with the first partition (15) and the second partition (16), and extends through the second channel (12), having a leading edge (21) which splits the flow of elastomer material following the second channel (12).