Extrusion Die Assembly for Patterning All Hollow Side Walls
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Solution Overview
Problem
Conventional extrusion dies for aluminum alloy products can only apply patterns to one pair of opposing side walls, limiting the ornamental and indicating capabilities of hollow products.
Innovation Solution
An extrusion die assembly with a mandrel, intermediate die, and lower die comprising first and second patterning tools that rotate to apply patterns simultaneously to both pairs of opposing side walls, featuring a retreating surface to absorb pressing forces and maintain the inner surface flat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional extrusion die with one patterning tool is used, then the device complexity is low, but the productivity is limited because patterns can only be applied to one pair of opposing side walls
Solution Approach 1:
The patent combines multiple patterning tools (first and second patterning tools) into a single extrusion die assembly, enabling simultaneous pattern application to both pairs of opposing side walls. This merging of multiple functional elements into one integrated system increases productivity without requiring separate processing steps
Solution Approach 2:
The extrusion die is designed with multi-functionality by incorporating both first and second patterning tools that can apply different patterns to different side walls simultaneously. The die structure serves multiple purposes: forming the hollow product, shrinking external dimensions, and applying patterns to all four side walls in one operation
2Manufacturing precision
If pressing forces are applied to the intermediate product during pattern application, then the pattern can be formed on the outer surface, but the inner surface may deform
Solution Approach 1:
The retreating surface is designed to counteract the pressing forces from the patterning tools before they can cause inner surface deformation. By providing this opposing support surface, the system prevents the harmful effect (inner surface deformation) that would otherwise result from the necessary pressing action
Solution Approach 2:
The retreating surface acts as an intermediary element between the patterning tools and the inner surface of the intermediate product. It mediates the interaction by absorbing excess pressing forces, allowing the patterning action to proceed while protecting the inner surface from deformation
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 simultaneous pattern application to multiple side walls, preventing inner surface deformation and allowing for arbitrary pattern selection and adjustment, enhancing ornamental and indicating functions.
Implementation Method 1
a first patterning tool that is rotated by a movement of the intermediate product to apply the pattern to at least one of outer surfaces of one of pairs of opposing side walls of the intermediate product; and a second patterning tool that is rotated by the movement of the intermediate product
Implementation Method 2
the mandrel may comprise the retreating surface that absorbs the pressing forces applied to the intermediate product from the first patterning tool and the second patterning tool
Data Source
AI summary
An extrusion die for applying patterns to multiple surfaces of a hollow intermediate product formed of thermoplastic material. The extrusion die comprises an upper die with a mandrel having a bearing to form a hollow space in the intermediate product; an intermediate die with a bearing to shrink external dimensions of the intermediate product; and a lower die supporting the upper die through the intermediate die. The lower die includes a first lower die with a first patterning tool that applies a pattern to surfaces of one pair of opposing side walls of the intermediate product, and a second patterning tool that applies a pattern to surfaces of another pair of opposing side walls of the intermediate product. Both patterning tools rotate with the intermediate product. A second lower die joins the first lower die to fix the second patterning tool.