Elastic Profile Extrusion with Contoured Pressing Wheel
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Solution Overview
Problem
Existing methods for manufacturing elastic profiles with longitudinally recurring transverse protrusions face challenges in achieving effective fusion bonding without damaging the protrusions, and there is a need for improved temperature control and energy efficiency in the process.
Innovation Solution
A method and apparatus involving a primary and secondary extruder, where the secondary extruder uses a molding wheel with recesses as molds for transverse protrusions, and a pressing wheel with recesses that allow it to press the substrate layer onto the primary profile without touching the protrusions, synchronized with the molding wheel's rotation, and the primary extruder's output is placed close to the joining point to minimize heat loss and optimize temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pressing wheel is used to press the substrate layer onto the primary profile, then the bond strength between profiles is improved, but the transverse protrusions may be damaged
Solution Approach 1:
The pressing wheel is designed with a surface geometry that matches the profile cross-section, creating locally adapted pressing zones. The pressing wheel has recesses or a contoured surface that corresponds to the shape of the transverse protrusions, allowing it to press the substrate layer onto the primary profile at specific locations while automatically avoiding contact with and damage to the protrusions.
2Ease of manufacture
If the primary extruder output is placed far from the joining point, then the apparatus layout is flexible, but heat loss increases and temperature control deteriorates
Solution Approach 1:
The primary extruder output is positioned in close proximity to the joining point where the secondary profile is formed. This preliminary positioning ensures that the extruded material reaches the joining zone while still at optimal temperature, minimizing heat loss during transport and eliminating the need for re-heating, thus improving energy efficiency and temperature control.
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 enables a stronger bond between the primary and secondary profiles without damaging the protrusions and improves energy efficiency by reducing heat loss and re-heating, resulting in a more effective and efficient manufacturing process.
Implementation Method 1
a rotating molding wheel forms a wall of the extrusion die, the molding wheel having recesses functioning as molds for the transverse protrusions within the extrusion die
Implementation Method 2
joining the primary profile and the substrate layer of the secondary profile through fusion bonding at a joining point, forming a composite structure
Implementation Method 3
extruding a primary profile at a primary extruder; extruding a secondary profile at a secondary extruder
Data Source
AI summary
A method of producing an elastic profile with longitudinally recurring transverse protrusions includes extruding a primary profile at a primary extruder; extruding a secondary profile at a secondary extruder, the secondary profile includes a substrate layer and transverse protrusions, the secondary extruder includes an extrusion die, wherein a rotating molding wheel forms a wall of the extrusion die, the molding wheel having recesses functioning as molds for the transverse protrusions within the extrusion die; joining the primary profile and the substrate layer of the secondary profile at a joining point for fusion bonding forming a composite structure. A rotating pressing wheel, may press on the composite structure against a bedding separate from the molding wheel. The primary profile may travel along an entirely straight path from the primary extruder to the joining point. The joining occurs at a nip formed between the molding wheel and a flat and stationary bedding.