Extrusion Tool for Continuous Fiber-Reinforced Foam Production
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Solution Overview
Problem
Existing methods for producing fiber/foam composites face challenges such as inability to embed fiber material into the foam, time-consuming and costly processes, and limited reinforcement in three spatial directions due to planar fiber material application and complex roll systems.
Innovation Solution
A tool with multiple inlet and outlet openings, including a multiway distributor, allows for simultaneous extrusion of fiber material and foamable polymer, embedding the fiber into the foam and enabling continuous, cost-effective production with two-dimensional structuring for enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fiber material is applied planar to the foam, then the production process is simpler, but the reinforcement in three spatial directions is limited
Solution Approach 1:
The patent transitions from planar (2D) fiber application to three-dimensional (3D) fiber embedding by using a multiway distributor to deliver foamable polymer to multiple outlet openings surrounding the fiber material, enabling the foam to grow in multiple directions and embed the fiber structure in 3D space
Solution Approach 2:
The patent divides the single outlet opening into multiple outlet openings (at least three) arranged around the fiber material, with each outlet receiving foamable polymer that expands to surround and embed the fiber structure from different directions, achieving 3D reinforcement
2Strength
If fiber material is embedded into the foam, then mechanical properties are improved, but the production process becomes more complex
Solution Approach 1:
The patent combines the fiber material and foamable polymer delivery systems into a single integrated tool with multiple outlet openings, eliminating the need for separate application steps and complex coordination between multiple devices while achieving 3D fiber embedding
Solution Approach 2:
The multiway distributor serves multiple functions: it distributes foamable polymer to multiple outlet openings, controls the foaming process in multiple directions, and enables 3D fiber embedding all within a single device component, reducing overall system complexity
3Productivity
If continuous production is implemented, then productivity is improved, but the ability to embed fiber material into foam is lost
Solution Approach 1:
The patent enables continuous production by implementing a continuous extrusion process where fiber material and foamable polymer are continuously fed through the tool with multiple outlet openings, maintaining uninterrupted manufacturing while achieving 3D fiber embedding through the multiway distributor system
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 tool enables uniform foaming and bonding of fiber/foam composites with improved mechanical stability, particularly high shear rigidity in all three spatial directions, while reducing the complexity and cost of the production process.
Implementation Method 1
extruding the foamable polymer through the second outlet opening and through the third outlet opening, with foaming of the foamable polymer to obtain a foam
Data Source
AI summary
The present invention relates to a tool (W) having at least one first inlet opening (E1) and at least one second inlet opening (E2), and also at least one first outlet opening (A1), at least one second outlet opening (A2) and at least one third outlet opening (A3), wherein the second outlet opening (A2) and the third outlet opening (A3) alternate with the first outlet opening (A1). The present invention further relates to a process for producing a fiber/foam composite by extruding through the tool (W) and to the use of the tool (W) for production of a fiber/foam composite by extrusion.