Extrusion Die Induction Heating for Uniform Aluminum Sheathing
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Solution Overview
Problem
Existing continuous extrusion apparatuses for sheathing core cables often result in imperfections or discontinuities in the extruded sheath, failing to maintain uniform temperature and efficient flow during the extrusion process.
Innovation Solution
A continuous extrusion apparatus with a rotatable wheel, die body, and electrical induction heating coils to maintain a uniform temperature of approximately 480°C, using thermocouples for temperature regulation, and divergent exit apertures with 90° elbows to ensure smooth flow and uniform sheath formation around the core cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heating methods are used in the die body, then temperature can be maintained, but temperature uniformity deteriorates and imperfections occur in the extruded sheath
Solution Approach 1:
The patent replaces conventional mechanical or radiant heating methods with electrical induction heating coils embedded in the die body. This electromagnetic heating method provides more uniform and controllable temperature distribution, eliminating hot spots and cold zones that cause sheath imperfections while maintaining the required extrusion temperature.
Solution Approach 2:
The patent modifies the heating parameters by using induction heating with specific coil configurations and power levels to achieve optimal temperature uniformity. The heating system is controlled to maintain temperature within a narrow range, preventing thermal gradients that would otherwise cause defects in the extruded sheath.
2Device complexity
If simple exit apertures are used in the die body, then device complexity is reduced, but flow uniformity deteriorates and discontinuities occur in the sheath
Solution Approach 1:
The patent employs divergent exit apertures with curved or angled geometries (90° elbows) instead of simple straight channels. These curved passages promote smooth material flow transitions, reduce turbulence and dead zones, and ensure uniform distribution of molten aluminum across the extrusion face, preventing sheath discontinuities.
Solution Approach 2:
The patent introduces three-dimensional divergent passages with varying cross-sections instead of two-dimensional flat channels. The passages expand and redirect material flow in multiple directions, creating more uniform velocity distribution and preventing flow stagnation that would cause defects in the extruded product.
3Device complexity
If the die body is fixed in position, then device complexity is reduced, but temperature control deteriorates and non-uniform heating occurs
Solution Approach 1:
The patent makes the die body movable rather than fixed, allowing it to be positioned optimally relative to the induction heating coils. The die body can be adjusted to ensure uniform electromagnetic field distribution across its surface, achieving consistent heating. The movable design also facilitates easy removal and maintenance while maintaining thermal uniformity during operation.
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 apparatus achieves a continuous, imperfection-free aluminum sheathing on core cables by maintaining a consistent temperature and uniform flow, ensuring a high-quality sheath without discontinuities and enhancing the extrusion process efficiency.
Implementation Method 1
An electrical induction heater including coils of copper tubing connected to an electrical power source and to a coolant circulating device is positioned at a radially outer portion of the die body and is energizable to supply heat to the die body
Implementation Method 2
coils of copper tubing connected to an electrical power source... is energizable to supply heat to the die body
Implementation Method 3
thermocouples are provided at locations in the die body radially inwardly and outwardly of the wheel from the extrusion chamber and are connected to provide a signal utilisable to regulate input of heat
Implementation Method 4
continuous extrusion of an aluminium sheathing free from imperfections or discontinuities on to a core cable... extrude through the annular extrusion orifice on to the core cable
Data Source
AI summary
Apparatus for continuous extrusion of an aluminium sheathing free from imperfections or discontinuities onto a core cable, such as an insulated copper cable, includes a rotatable wheel formed with a pair of circumferential grooves arcuate tooling bounding radially outer portions of the respective grooves, a die body provided with divergent exit apertures discharging laterally to an extrusion chamber through 90° elbows and short divergent passages at diametrically opposed locations. An electrical induction heater includes coils of copper tubing connected to an electrical power source and to a coolant circulating device is positioned at a radially outer portion of the die body and is energizable to supply heat to the die body to maintain a uniform temperature of approximately 480° C., controlled by signals from thermocouples around the extrusion chamber.