Extrusion Tool With Separated Reinforcing Rod Channels
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Solution Overview
Problem
Existing extrusion tools for manufacturing plastic profiles with reinforcing elements, such as glass or carbon fibers, face challenges in achieving high mechanical rigidity while avoiding thermal bridges and minimizing expansion/retraction due to temperature changes, particularly in carpentry applications like windows and doors.
Innovation Solution
An extrusion tool design with channels for inserting continuous reinforcing rods that are separated from the plastic material passages, allowing for seamless transition and insertion without interference, enabling the production of profiles with and without reinforcing elements without interruption, using a die with an inlet block and a punch held by fins, and incorporating contactless heating of the rods to enhance cohesion with the plastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal sections are used for reinforcement, then mechanical strength is improved, but thermal bridges are created causing unwanted thermal expansion and contraction
Solution Approach 1:
The patent changes the material parameter from metal to non-metallic reinforcing elements (glass fibers, carbon fibers, or plastic fibers). This material substitution maintains the mechanical reinforcement function while eliminating the thermal conductivity issue, as these alternative materials have lower thermal conductivity than metal, thus reducing thermal bridge effects.
Solution Approach 2:
The patent employs composite materials by combining plastic matrix material with non-metallic reinforcing elements (glass fibers, carbon fibers, or plastic fibers). This composite structure provides the necessary mechanical strength while avoiding the thermal bridge problem inherent in metal reinforcements, creating a multi-material solution that balances strength and thermal performance.
2Strength
If channels for reinforcing elements are integrated into the die, then reinforcement is achieved, but the passages for plastic material are interfered with
Solution Approach 1:
The patent segments the die structure into separate functional zones: dedicated channels for reinforcing elements and separate passages for plastic material. By dividing the die into distinct regions with independent flow paths, the design allows reinforcing elements to be incorporated without interfering with plastic material flow, simplifying the overall structure while achieving reinforcement.
Solution Approach 2:
The patent extracts the reinforcing element channels from the main plastic material passage. By separating the channels for reinforcing elements from the plastic material passages, the design eliminates interference between the two material flows, allowing independent optimization of each path while maintaining structural integrity.
3Reliability
If channels open into plastic passages close to the outlet, then plastic material does not infiltrate channels, but the transition zone becomes complex
Solution Approach 1:
The patent applies local quality by creating a specific geometric configuration at the outlet zone where channels open into plastic passages. By optimizing the local geometry at this critical transition zone, the design ensures that plastic material does not infiltrate the channels while maintaining a manageable structure. The local quality adjustment allows reliable material flow control without requiring complex overall die design.
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
This solution enhances the mechanical properties of plastic profiles, reduces thermal expansion, and allows for flexible production without interrupting the extrusion process, while avoiding the use of metal sections that could create thermal bridges, thus improving the rigidity and durability of thermoplastic profiles.
Implementation Method 1
injecting the plastic material, under high pressure, into passages passing through successive blocks
Implementation Method 2
only open into these passages in a zone close to the outlet where the pressure of the injected plastic material has become low enough so that, in the absence of rods, the plastic material does not infiltrate the channels
Implementation Method 3
prior to the insertion of the rods (C1-C4), said rods (C1-C4) are heated to a temperature T0 of between 220°C and 350°C
Data Source
Figure 1~8
Figure 3~5
Figure 6~7
AI summary
The invention relates to extrusion equipment for manufacturing plastic profile members having reinforcing elements, said extrusion equipment including: a channel (1) having an inlet unit (1a) for high-pressure injection of the plastic into passages (4b, 4c, 5b, 5c, ...7b, 7c) that pass through consecutive units (1a - 1e) so as to gradually give the shape thereof to the profile member up to an outlet opening leading out to the final profile; and a mandrel (3a, 3e) that is kept, by means of vanes, inside the passages for the plastic. The equipment comprises channels (C1 - C2) for inserting continuous reinforcing rods (J1 - J2) that form the reinforcing elements, and said channels (C1 - C2) are separate, over the main portion of the path thereof, from the passages (4b, 4c, 5b, 5c, ...7b, 7c) for the plastic and lead only into an area (8b, 8c) of said passages near the outlet where the pressure of the injected plastic has become sufficiently low so that, in the absence of the rods, the plastic does not seep into the channels.