Double-Belt Press Thermoplastic Granulate Production
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Solution Overview
Problem
The production of thermoplastic granulate materials using extruders requires high energy input, leads to increased production costs, and results in mixed shades rather than desired speckled or structured patterns due to particle mixing, especially when using abrasive filler materials, which causes extruder wear and complex feeding requirements.
Innovation Solution
The method involves dispensing with extruders by using a double-belt press (Thermofix press) to produce a web-shaped dimensionally stable body from a pourable thermoplastic intermediate substrate, which is then comminuted to create granulate materials with varied colors and characteristics, allowing for flexible particle size distribution and color transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extruders are used to produce thermoplastic granulate materials, then a dimensionally stable body can be generated, but high energy input is required and production costs increase
Solution Approach 1:
The patent extracts and removes the extruder from the production process entirely. Instead of using an extruder to generate the dimensionally stable body, the invention uses a double-belt press to form a web-shaped intermediate product directly from the powdered mixture, thereby eliminating the high energy input associated with extrusion while achieving the same functional result.
Solution Approach 2:
The double-belt press is used for multiple purposes: it both forms the web-shaped intermediate body and enables subsequent comminution to produce granulate materials with varied colors and characteristics. This multi-functional approach replaces the specialized extruder and reduces overall energy consumption.
2Manufacturing precision
If extruders are used to produce thermoplastic granulate materials, then a dimensionally stable body can be generated, but production costs increase
Solution Approach 1:
The patent removes the extruder from the production line, eliminating the high capital and operational costs associated with extrusion equipment. The double-belt press system is used instead, which reduces both equipment investment and production costs while maintaining the ability to produce dimensionally stable intermediate bodies.
Solution Approach 2:
The invention employs a simpler, less expensive forming mechanism using the double-belt press rather than costly extrusion equipment. The web-shaped intermediate body is formed through a simpler process that reduces manufacturing costs while still achieving the required dimensional stability for subsequent granulation.
3Productivity
If extruders are used with abrasive filler materials, then granulate materials can be produced, but extruder wear increases
Solution Approach 1:
The patent removes the extruder from the process, eliminating the wear problem entirely. The double-belt press forms the web-shaped intermediate body without direct contact between abrasive fillers and extruder components, and the subsequent comminution process does not subject the forming mechanism to the same wear as extrusion equipment would experience.
Solution Approach 2:
Instead of using an extruder to force material through a die, the invention uses a comminutor to cut and size the web-shaped intermediate body. This copying of the granulation function through a different mechanism (comminution rather than extrusion) avoids the wear issues associated with abrasive fillers in extruder barrels and screws.
4Manufacturing precision
If extruders are used to produce thermoplastic granulate materials, then a dimensionally stable body can be generated, but complex feeding requirements arise
Solution Approach 1:
The patent removes the extruder and its complex feeding system. The double-belt press accepts the powdered mixture more directly, and the web-shaped intermediate body is formed through a simpler process that does not require the sophisticated feeding mechanisms needed for extrusion, thereby reducing device complexity.
Solution Approach 2:
The invention replaces the mechanical extrusion system with a thermal pressing system using the double-belt press. The web-shaped intermediate body is formed through heat and pressure application to the powdered mixture on the belts, which is a simpler mechanical process than extrusion that does not require complex feeding systems to maintain precise material flow and pressure.
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 production costs, enhances color and design diversity in final products, and minimizes extruder wear by eliminating the need for extruders, while enabling the production of granulate materials with distinct color layers and mechanical characteristics suitable for complex patterns.
Implementation Method 1
the heating is generated by means of the mechanical energy of the stirring during stirring/mixing
Implementation Method 2
a thermoplastic web is understood as a belt-shaped body comprising at least thermoplastic material particles which during the manufacturing process have been thermally fixed with each other
Data Source
AI summary
In the production of thermoplastic granulate material, after mixing the starting materials, it is common in the state of the art for these materials to be kneaded and compressed in extruders, with subsequent granulation. According to the invention, no extruder is used, rather the starting materials for the thermoplastic granulate material are supplied directly to a double belt press after the mixing. Subsequently, the generated web-type to sheet-type body is processed into a granulate material by means of grinding, or is used as a web-type, sheet-type, strip-type or film-type intermediate product for the production of a further intermediate product or end products.