Extruded Plastic Profiles with Continuous Insulation Foam
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Solution Overview
Problem
Existing processes for producing profiles with a foamed core and thermoplastic jacket face issues such as non-uniform foam distribution, energy inefficiencies, and complex process technology due to the need for hot extrusion and limited ability to produce profiles with multiple foam chambers.
Innovation Solution
A continuous process involving a gripper-belt system where a liquid reactive polyurethane foam system is introduced, shaped, and then coated with a thermoplastic jacket, allowing for uniform foam development and simplification of process technology, enabling the production of profiles with multiple foam chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reactive system for foamed plastic is passed through the hot extruder die system, then the profile can be produced in a single operation, but energy consumption increases and process technology becomes more complex
Solution Approach 1:
The process is divided into two separate operations: first producing the thermoplastic profile structure, then subsequently introducing and foaming the polyurethane reactive system within the profile chambers. This segmentation allows each material to be processed under its optimal conditions without energy waste from heating the reactive system.
Solution Approach 2:
The thermoplastic profile structure is produced in advance through extrusion before the polyurethane foaming takes place. This preliminary action creates the container structure that will later hold and contain the foam expansion, enabling sequential processing rather than simultaneous heating of all materials.
2Productivity
If gases introduced into the cavity of the jacket during foaming are dissipated by the extruder die system, then foaming can proceed, but the foam obtained is not uniform
Solution Approach 1:
A foil is introduced as an intermediary element between the polyurethane reactive system and the atmosphere. This foil encloses the reactive system during injection and foaming, preventing gas escape and ensuring uniform foam distribution throughout the profile chambers without interference from the extruder die system.
3Productivity
If the profile is produced hot from extrusion, then the extrusion process is efficient, but the subsequent filling with foamable material is adversely affected
Solution Approach 1:
The thermoplastic profile is extruded in advance to establish the structural framework and chambers. This preliminary structure creation allows subsequent cooling of the profile before foam injection, ensuring optimal conditions for uniform foam expansion and filling without compromising extrusion efficiency.
Solution Approach 2:
The process maintains continuous production by extruding profiles continuously, then subsequently and continuously introducing and foaming the polyurethane system in the cooled profiles. This sequential continuity preserves extrusion efficiency while ensuring proper foam filling conditions.
4Productivity
If a lance is used to introduce the reactive system into the profile, then foaming can be achieved, but only profiles with one chamber can be produced
Solution Approach 1:
The foil acts as a versatile intermediary that can be configured to enclose multiple separate reactive system introductions into different chambers. This approach enables the production of profiles with one or more foam chambers, providing adaptability for various profile designs without requiring different injection methods.
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 uniform and homogeneous foam distribution within the profile, reduces energy consumption, and simplifies the production process, enabling the creation of profiles with multiple foam chambers while maintaining ideal foam development conditions.
Implementation Method 1
introducing at least one liquid foamable reactive system of the core comprising a polyisocyanate a) and at least one higher molecular compound having groups reactive towards isocyanate groups b) into the gripper-belt system
Implementation Method 2
introducing the core from step (C) or (D) into an extruder with attached extrusion die for producing hollow profiles, in order to sheath the core with a jacket made of at least one thermoplastic material
Data Source
AI summary
The present invention relates to a continuous process for producing a profile comprising at least one core made of a polyurethane foam or a mixture comprising a polyurethane foam, at least one jacket made of at least one thermoplastic material, and optionally at least one foil between core and jacket, to a profile produced via said process, to the use of this profile for producing windowframes, doorframes, or in the fitting-out of interiors, or in apparatuses in which, during operation, temperature differences arise between interior space and exterior space, and also to an apparatus for carrying out the process of the invention.