Slim Extruder Welding Device With Rotatable Coupling
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Solution Overview
Problem
Conventional manual welding extruders are bulky, heavy, and difficult to maneuver in tight spaces due to their design and the weight of hydraulic systems, making them inefficient for accessing hard-to-reach welding points.
Innovation Solution
A slim, lightweight manual welding extruder with a rod-shaped housing and electric drive, featuring a rotatable coupling for flexible connecting lines that allows independent movement of the welding unit and a quasi-stationary supply unit, enabling precise temperature control and ergonomic handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional manual welding extruders use hydraulic drive systems, then sufficient driving force is achieved, but the device becomes heavy and complex
Solution Approach 1:
The patent replaces the hydraulic drive system with an electric motor and gear mechanism. The electric motor (20) is connected via a gear (21) to the extruder screw shaft (22), eliminating the need for hydraulic pumps, fluid reservoirs, and complex hydraulic control systems while providing sufficient driving force for plasticizing the welding wire.
Solution Approach 2:
The patent separates the control unit (3) from the welding unit (2), connecting them via flexible connecting lines (4, 5). This extraction of the heavy control and power supply components from the handheld welding unit reduces the weight and complexity of the moving part, while the supply unit can remain stationary or be more easily maneuvered.
2Stability of the object's composition
If conventional welding extruders have a bulky design with lateral handles, then structural stability is maintained, but the device becomes difficult to maneuver in tight spaces
Solution Approach 1:
The patent divides the welding extruder into two separate units: a handheld welding unit (2) and a stationary supply unit (3). The welding unit contains only the essential components (extruder screw, heating elements, nozzle) and can be easily maneuvered into tight spaces, while the supply unit houses the electric motor, control systems, and power supply.
Solution Approach 2:
The patent changes the spatial arrangement from a lateral handle configuration to a longitudinal rod-shaped design. The connections for the connecting lines are provided as an extension of the handle on the rod-shaped housing, emphasizing the slim, cylindrical design that allows access to confined welding areas.
3Stability of the object's composition
If the welding unit and supply unit are firmly connected, then structural stability is maintained, but the device becomes difficult to guide in inaccessible places
Solution Approach 1:
The patent makes the connection between the welding unit and supply unit flexible rather than rigid. The flexible connecting lines (4, 5) allow the welding unit to be rotated and maneuvered independently in three-dimensional space, enabling access to inaccessible welding positions while maintaining functional connection for power and control signals.
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 design enhances usability in confined spaces, reduces operator fatigue, and allows for precise control of welding parameters, improving accessibility and efficiency in extrusion welding processes.
Implementation Method 1
The plasticizing screw unit heats the welding wire and conveys it as a plasticized strand of plastic with an extruder screw via a welding shoe
Implementation Method 2
the plastic materials are heated with hot air in an area around the respective welding point. For this purpose, the extruder welding device usually has an integrated hot air generating device with internal or external air supply, which heats a cold air flow supplied and applies a hot air jet to the point of the plastic materials to be welded
Implementation Method 3
The plasticizing screw unit heats the welding wire and conveys it as a plasticized strand of plastic with an extruder screw via a welding shoe with an outlet nozzle at the front end of the plasticizing screw unit to the welding point
Implementation Method 4
flexible connecting lines, for example a hose line for the air supply and electrical connecting lines accommodated therein, are connected to the welding unit and/or the supply unit via a rotatable coupling. The effect of this is that the welding unit can be easily rotated relative to the supply unit in the circumferential direction without the connecting line winding up
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a hand welding extruder (1) for welding thermoplastic plastic materials by means of a plasticized plastic strand (26) having a plasticization worm unit (24) connected to a drive motor (20) by a gearbox (21), and having a hot air generation device (27) with an external air supply, the plasticizer worm unit, the gearbox, the drive motor, and the hot air generation device being disposed in a common housing. The proposed hand welding extruder has a bar-shaped housing having a front weld segment (7) and a grab handle (8) connected thereto in the longitudinal direction. The plasticizer worm unit and the hot air generation device are disposed in the bar-shaped housing in the welding segment and an electric motor (20) is disposed in the grab handle. The electric motor is connected to a shaft of the extruder worm (23) via a gearbox, the gearbox being potentially provided in the grab handle and/or the welding segment of the bar-shaped housing of the hand weld extruder.