Thermoplastic Double-Wall Plate Welding for Flatness
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Solution Overview
Problem
Existing methods for producing large thermoplastic double-wall structures face challenges in achieving consistent quality and strength due to uneven and slow heat dissipation during the bonding process, leading to thermal stresses and defects like twisted plates.
Innovation Solution
The method involves arranging elongated hollow profiles in parallel and welding them together from both sides using extrusion welding, ensuring uniform heating and surface welding to create a rigid double-wall structure with improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extrusion methods are used to produce large thermoplastic double-wall structures, then production is possible, but uneven and slow heat dissipation leads to thermal stresses and quality inconsistencies
Solution Approach 1:
The plate is divided into multiple identical hollow profile sections that are produced separately and then joined together. This segmentation allows each section to be manufactured with consistent quality control while maintaining overall production efficiency for large structures.
Solution Approach 2:
The welding process is applied from both sides of the plate simultaneously, adding a dimensional aspect to heat application. This bidirectional welding approach ensures uniform heat distribution and eliminates the uneven cooling problems of conventional single-sided methods.
2Device complexity
If conventional single-sided welding is used, then production process is simple, but uneven heating causes thermal stresses and twisted plates
Solution Approach 1:
The welding setup uses asymmetric positioning of heating elements on opposite sides of the plate, with each side's elements positioned to correspond to the other. This asymmetric arrangement enables symmetric heat distribution, preventing thermal stress accumulation and maintaining plate flatness.
Solution Approach 2:
The heating system creates equipotential temperature distribution across the plate by applying heat from both sides simultaneously. This ensures that all regions of the plate experience equivalent thermal conditions, preventing differential expansion and maintaining structural stability.
3Strength
If thick double-wall constructions are produced by extrusion, then structural strength is improved, but heat removal becomes insufficient leading to production difficulties
Solution Approach 1:
Thick plates are constructed by joining multiple hollow profile sections rather than producing them as single extruded pieces. This segmentation allows efficient heat removal from each individual section while achieving the desired overall thickness and strength through assembly.
Solution Approach 2:
Heat is applied and removed from both sides of the plate simultaneously, utilizing the third dimension (thickness) more effectively. This bidirectional thermal management enables efficient heat dissipation in thick constructions that would be impossible with single-sided processing.
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 allows for the production of thermoplastic double-wall structures with high flexural rigidity and consistent quality, reducing thermal stresses and production costs, while enabling easy inspection of welds and facilitating recycling, corrosion resistance, and durable color retention.
Implementation Method 1
The welding is carried out simultaneously from both sides of the stack
Implementation Method 2
the hollow profiles are welded together so that adjacent hollow profiles are joined by welded seams
Implementation Method 3
In a preferred embodiment, double-walled plates are made of thermoplastics by welding the corresponding tube profiles
Data Source
AI summary
A method of producing a plate-like construction having a double-wall structure and its use. According to the present invention, several elongated profiles which have essentially straight central axes are arranged against each other in such a way that adjacent hollow profiles abut each other and together form, in general terms, a flat stack having two opposite sides. The hollow profiles are welded together in order to join them with welded seams, in which case the welding is essentially carried out simultaneously from both sides of the stack. Besides good flexural strength and the opportunity to recycle, thermoplastic plates which are produced by means of the present method exhibit resistance to corrosion, decay and mould.