Imitation Branch Surface Modification via Bubble Cooling
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Solution Overview
Problem
Natural branches used in making separating walls and decorative materials deteriorate over time, becoming unaesthetic and allowing visibility, whereas existing methods for producing imitation branches lack the ability to create irregular surface patterns unpredictably.
Innovation Solution
A method involving melting a polymer mass under pressure, extruding it into an elongate plastic strand, cooling it while submerged in a moving medium with air or nitrogen bubbles introduced for irregular insulation, and applying after-treatments to create an irregular surface structure mimicking natural branches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural branches are used to make separating walls and decorative materials, then the product has an aesthetic natural appearance, but the branches deteriorate over time (approximately 5 years), become unaesthetic and allow visibility through the product
Solution Approach 1:
The patent creates imitation branches that copy the aesthetic appearance of natural branches through extrusion processes. The plastic strand is formed with surface modifications including irregularities, knots, and natural patterns that replicate the look of real branches, providing a permanent alternative that maintains aesthetics throughout its service life.
Solution Approach 2:
The patent uses parameter changes in the cooling process to create realistic branch appearances. By controlling cooling rates and introducing air bubbles during cooling, the plastic develops surface characteristics that mimic natural branch textures, knots, and irregularities, achieving both longevity and aesthetic appeal.
2Shape
If air and nitrogen bubbles are introduced into the cooling medium during plastic strand cooling, then the outer surface of the plastic strand is provided with irregular modifications to the surface structure mimicking natural branches, but the cooling process becomes more complex
Solution Approach 1:
Air and nitrogen bubbles act as intermediaries during the cooling process. These bubbles are introduced into the cooling water to create temporary insulation zones on the plastic strand surface, causing localized variations in cooling rates that produce natural-looking irregularities, knots, and surface modifications without requiring complex mechanical intervention.
Solution Approach 2:
The patent employs pneumatic principles by introducing gas bubbles (air and nitrogen) into the liquid cooling medium. This hydraulic-pneumatic system creates controlled turbulence and insulation effects during cooling, generating realistic surface patterns on the imitation branches through fluid dynamics rather than mechanical means.
3Shape
If the plastic strand is completely submerged in the cooling medium for at least part of its path, then the plastic strand is provided with indentations across its entire periphery, but the submergence control becomes more difficult
Solution Approach 1:
The patent implements dynamic submergence control where the plastic strand is partially or fully submerged in the cooling medium during specific portions of its path. The system allows the strand to move in and out of the cooling bath, with air bubbles continuously introduced to maintain submergence and create uniform peripheral indentations throughout the strand length.
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 method produces long-lasting, recyclable, UV-resistant imitation branches with a natural appearance, offering a service life of at least 15 years and preventing deterioration, while allowing for unpredictable surface pattern formation.
Implementation Method 1
air and/or nitrogen bubbles are provided on at least part of the outer surface of the plastic strand, which bubbles at irregular locations insulate the surface of the plastic strand from the cooling medium
Implementation Method 2
the plastic strand is at least partly drawn through a moving cooling medium during cooling, as a result of which an irregular and turbulent way of cooling is created
Implementation Method 3
a polymer mass is melted under pressure, is then forced through an extruder head
Data Source
Figure 1a~1d
Figure 2a~2b
AI summary
The present invention relates to a method for producing imitation branches (1), in which a polymer mass is melted under pressure, is then forced through an extruder head (2) and is drawn from said extruder head (2) in the form of an elongate plastic strand (3), which is subsequently cooled and is shortened to the desired length, in which the plastic strand (3) is at least partly drawn through a moving cooling medium during cooling in which the plastic strand is completely submerged in said cooling medium for at least a part of its path in order to at least partly provide the outer surface of the plastic strand (3) with modifications to the surface structure. By using a moving cooling medium (4), irregular cooling is achieved so that a plastic strand (3) having an irregularly shaped outer surface is produced which imitates a natural branch virtually perfectly.