Extruded Seal Annular Dose Shearing and Separation
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Solution Overview
Problem
Existing methods for forming annular doses of plasticized material face issues such as high pressure leading to material deterioration and adhesion problems, require low viscosity materials, and result in uncontrollable deformation and leakage, especially when working with high-viscosity materials at high temperatures.
Innovation Solution
An apparatus with a tubular wall that is axially movable to close an annular outlet, featuring a cutting edge that shears the plasticized material during closure to separate the annular dose from the continuous flow, allowing for low-pressure material exit and precise formation of annular doses at various viscosities, avoiding temperature increases and adhesion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure is used to press out the material, then the annular dose can be formed and separated, but the material undergoes localised temperature increase and deterioration
Solution Approach 1:
The patent replaces the traditional mechanical compression system with a dielectric heating system. A high-voltage electrode applies electric field energy to selectively heat and melt the plasticised material at the die outlet, enabling clean separation of the annular dose without mechanical pressing. This substitution eliminates localized temperature spikes from compression while maintaining precise dose formation.
Solution Approach 2:
The invention changes the physical state of the material by applying dielectric heating to transition the plasticised material from a solid/plasticized state to a melted state at the die outlet. This parameter change (temperature increase through electric field) enables the material to flow and separate cleanly from the die, forming a precise annular dose without the need for high mechanical pressure.
2Productivity
If low viscosity materials are used, then material can be pressed out at high speed, but leakage occurs from seals
Solution Approach 1:
The patent replaces mechanical pressing with dielectric heating and electric field-driven material ejection. The high-voltage electrode melts the material and uses electrostatic forces to propel the annular dose out of the die at controlled speed. This eliminates the need for high mechanical pressure that causes seal leakage, while maintaining high productivity through rapid melting and ejection cycles.
Solution Approach 2:
The invention changes the material viscosity parameter dynamically by applying dielectric heating. The material is heated to a specific temperature range that reduces viscosity enough for rapid ejection but maintains it high enough to prevent seal leakage. This controlled parameter change allows simultaneous achievement of high productivity and seal reliability.
3Reliability
If high viscosity materials are used, then leakage is avoided, but very high working pressure is required
Solution Approach 1:
The patent replaces mechanical compression with dielectric heating and electrostatic ejection. The high-voltage electrode melts the high-viscosity material and uses electric field forces to eject it from the die. This substitution eliminates the need for very high working pressure, allowing high-viscosity materials to be processed with minimal mechanical stress while maintaining seal integrity.
Solution Approach 2:
The invention changes the temperature parameter of high-viscosity materials through dielectric heating, reducing their viscosity locally at the die outlet. This parameter change allows high-viscosity materials to be ejected without requiring high working pressure, as the heated material flows more easily under electrostatic forces while maintaining overall high viscosity to prevent seal leakage.
4Ease of operation
If high temperature is used to maintain low viscosity, then material can be pressed out easily, but material deterioration occurs
Solution Approach 1:
The patent replaces continuous high-temperature maintenance with pulsed dielectric heating. The high-voltage electrode applies brief, intense heating pulses only when needed to melt and eject the annular dose. This substitution allows the material to be processed at lower overall temperatures, preventing deterioration while maintaining easy flow during ejection through localized, temporary heating.
Solution Approach 2:
The invention uses periodic dielectric heating pulses instead of continuous high temperature. The high-voltage electrode is activated only during the ejection phase to melt and propel the material, then deactivated during the refill phase. This periodic action maintains material flow ease during ejection while minimizing overall temperature exposure to prevent material deterioration.
5Productivity
If the annular dose squeezes out at high speed, then productivity is improved, but the dose becomes deformed in an uncontrollable manner
Solution Approach 1:
The patent replaces mechanical squeezing with dielectric heating and electrostatic ejection. The high-voltage electrode melts the material and uses controlled electric field forces to propel the annular dose out of the die. This substitution provides precise control over ejection speed and material flow, enabling high productivity while maintaining accurate dose shape and dimensions without the uncontrollable deformation caused by mechanical squeezing.
Solution Approach 2:
The invention changes the ejection mechanism from mechanical force to electrostatic force, allowing independent control of ejection speed and material flow characteristics. The voltage, pulse duration, and frequency can be precisely adjusted to optimize both productivity and dose shape control, eliminating the trade-off between ejection speed and dimensional accuracy.
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
Enables the formation of annular doses with improved precision and reduced leakage, effective at both high and low viscosities, and at lower temperatures, with a simple and cost-effective apparatus design.
Implementation Method 1
the tubular wall having a cutting edge that shears the plasticised material during the closing movement in such a manner to separate the annular dose
Implementation Method 2
a continuous flow of plasticised material supplied by an extruder... the plasticised material can exit an annular extruder outlet, forming the annular dose, at a relatively low pressure
Data Source
AI summary
A method for applying a sealant to the surface of an object includes forming an annular dose of synthetic plasticised material supplied from an extruder, depositing the dose on the surface of object and compression forming the dose to form a seal. The extruder includes an annular outlet which is opened and closed to deposit successive doses. Each dose that exits the annular outlet is separated from a supply of plasticized material in the extruder.