Extruded Plastic Profile With Continuous Foam Core
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Solution Overview
Problem
Existing methods for producing profiles with foamed cores and thermoplastic jackets face challenges such as uneven foam distribution, energy inefficiency due to the reactive system passing through a hot extruder die, and the inability to produce multiple foamed chambers simultaneously.
Innovation Solution
A continuous process that introduces a foamable reactive system into a jaw belt with a pre-formed film, allowing for even foaming and subsequent covering with a thermoplastic jacket without an inner pipe, enabling homogeneous foam distribution and ideal foaming conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a foamable reactive system is introduced into a hot extruder die, then the thermoplastic shell is formed, but the foam distribution becomes uneven and energy consumption increases
Solution Approach 1:
The foamable reactive system is introduced into the die strip before the extrusion process begins, allowing the foam to form in advance at ambient temperature. This preliminary foaming action avoids the need to guide the reactive system through the hot extruder die, preventing uneven foam distribution and reducing energy consumption.
Solution Approach 2:
The process separates the foaming operation from the extrusion operation. The foamable reactive system is introduced and foamed in the die strip (first segment), then the pre-formed foam core is encased by the thermoplastic shell in the extruder (second segment). This segmentation allows each process to occur under optimal conditions independently.
2Reliability
If an inner tube is used to guide the reactive system, then the foam can be formed, but the device complexity increases
Solution Approach 1:
The inner tube component is completely removed from the system. Instead of using an inner tube to guide the reactive system through the extruder, the foamable reactive system is directly introduced into the die strip where it foams in place. This extraction simplifies the device structure while maintaining reliable foam formation.
Solution Approach 2:
The die strip itself serves as the intermediary structure that contains and shapes the foamable reactive system during foaming. The film in the die strip acts as the containing structure, replacing the need for an inner tube while enabling direct introduction of the reactive system.
3Productivity
If the reactive system is guided through the hot extruder die, then the shell material is introduced, but the foam distribution becomes non-uniform
Solution Approach 1:
The foamable reactive system is introduced and allowed to foam completely before the shell material is applied. This preliminary foaming action occurs in the die strip at ambient temperature, ensuring uniform foam formation. The pre-formed foam core is then continuously encased by the thermoplastic shell in the extruder, maintaining both productivity and foam homogeneity.
4Adaptability or versatility
If a single foamable mixture is used, then the process is simple, but multiple foamed chambers cannot be produced simultaneously
Solution Approach 1:
The die strip is divided into multiple separate cavities or chambers, each capable of receiving and foaming its own foamable reactive system independently. This segmentation of the die strip structure enables the simultaneous production of multiple foamed chambers while maintaining process simplicity, as each chamber operates independently during the continuous extrusion process.
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 process achieves a stable and homogeneous foam distribution within the profile, reduces energy consumption, and allows for the production of profiles with multiple foamed chambers, enhancing the efficiency and quality of the manufacturing process.
Implementation Method 1
introducing at least one foamable reactive system into the die strip, wherein the at least one foamable reactive system reacts to form a core
Implementation Method 2
the at least one foamable reactive system reacts to form a core
Implementation Method 3
encase the core with a jacket of at least one thermoplastic material to obtain the profile
Data Source
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AI summary
The invention relates to a continuous method for producing a profiled element (1) containing at least one core made of a polyurethane foam or a mixture containing a polyurethane foam, at least one jacket made of at least one thermoplastic material, and optionally at least one film (11) between the core and the jacket, to a profiled element (1) produced by said method, to the use of such a profiled element to produce window frames and door frames, in interior finishing, and in devices in which temperature differences between the interior and exterior occur during operation, and to a device for carrying out the method according to the invention.