Counter-Rotating Dies for Wide Profile Extrusion Stability
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Solution Overview
Problem
Existing methods for continuous pressing of thermally mouldable materials using rotary dies face challenges with high radial bearing forces, limited profile width, and difficulties in producing profiles with varied cross-sections and patterns, leading to costly and complex tooling, as well as issues with adhesion and process stability.
Innovation Solution
The use of two rotating dies that cancel out radial forces, allowing for independent positioning and adjustment, enabling the extrusion of profiles with varied thickness and patterns, including hollow sections, while minimizing adhesion and tool complexity by synchronizing material feeding speed and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single rotating die is used to extrude profiles with patterns and varied cross-sections, then profile design flexibility is improved, but radial bearing forces increase causing die bending and bearing breakdown
Solution Approach 1:
The patent employs a counter-rotating die that generates opposing radial forces to balance and cancel out the radial forces produced by the primary rotating die. This counterweight principle allows the system to handle complex profile designs with varied cross-sections and patterns without subjecting the bearing system to excessive unbalanced radial loads, thereby preventing die bending and bearing breakdown while maintaining profile design flexibility.
Solution Approach 2:
The patent introduces asymmetry by using two rotating dies with different configurations - one die creates the desired profile pattern while the other die is designed to counterbalance the radial forces. The asymmetric arrangement of the dies and their respective patterns allows for complex profile designs while the opposing die ensures force balance, resolving the contradiction between design flexibility and structural strength.
2Ease of manufacture
If rotary dies are used to extrude profiles with varied cross-sections, then manufacturing cost is reduced compared to machining, but device complexity increases
Solution Approach 1:
The patent makes the bearing surfaces universal by designing them to perform multiple functions: they not only define the profile cross-section shape but also generate the necessary radial counterbalancing forces. The bearing surfaces are configured to accommodate different profile designs while maintaining force balance, allowing the same tooling system to produce various profile types without requiring completely different tooling setups, thus reducing manufacturing costs while controlling complexity.
Solution Approach 2:
The patent segments the profile formation process into two independent rotating die systems, each responsible for specific aspects of profile creation and force balancing. This segmentation allows each die to be optimized for its specific function while working in coordination with the other, enabling complex profile designs to be achieved through modular, interchangeable components that reduce overall manufacturing costs and simplify maintenance.
3Manufacturing precision
If high pressure is applied to extrude materials requiring high plasticity, then material flow is improved, but rotating die bending and bearing failure increase
Solution Approach 1:
The patent applies the counterweight principle to balance the radial forces generated during high-pressure extrusion of materials requiring high plasticity. The counter-rotating die produces opposing forces that cancel out the bending moments and radial loads on the primary die, allowing high extrusion pressures to be applied without causing die bending or bearing failure, thereby maintaining both material flow quality and process stability.
4Adaptability or versatility
If profile output speed is varied to produce profiles with varied cross-section, then profile design flexibility is improved, but adhesion and process stability problems increase
Solution Approach 1:
The patent employs dynamic control of the rotating die speeds and positions to accommodate varied profile output requirements. The system can adjust the rotational velocities of the dies independently, allowing for accelerated or decelerated material flow at different sections of the profile while maintaining synchronized force balance. This dynamic adjustment capability enables complex varied cross-section designs without causing adhesion problems or process instability.
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
This approach reduces manufacturing costs, allows for simultaneous extrusion of multiple profiles, and stabilizes the process by eliminating 80-98% of radial bearing forces, enabling efficient production of profiles with complex geometries without tool breakdowns.
Implementation Method 1
Contact of the rotating dies with each other cancel out each other main radial forces
Data Source
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AI summary
The invention relates to device and method enabling industrial continuous pressing, called extrusion of plastically / thermally mouldable substances (11) such as metal, composite metal, plastic, composite or rubber, which is pressed to the profile (12) by a process comprising tool fixed member (6) partially predefining the profile shape / cross-section before the profile finally defined to fixed or varied cross-section when the material passes rotating dies (2) which can be patterned or smooth and through the contact with each other (1) cancel out each main radial forces and the position of which in some embodiments of the invention may vary relative to other bearing surfaces (13, 17) or rotary bearing surfaces (4) of the tool with which they define the final shape of the profile.The invention enables the extrusion of pattern on the inside of hollow profiles and the extrusion of multiple profiles in one tool, because 80-98% of the radial bearing forces are eliminated, allowing the installation of rotary dies where not previously possible, and almost unlimited opportunities in increased profile width.