Insulating Bar Manufacturing via Extrusion Segmentation
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Solution Overview
Problem
The existing methods for manufacturing insulating bars with corrugated structures for composite profiles are costly and inefficient, requiring complex and expensive tools for extrusion and injection molding, and struggle to maintain dimensional accuracy for connection strips, leading to increased production time and material waste.
Innovation Solution
A method involving continuous extrusion or pultrusion of a band-like plastics material with a rectangular cross section, followed by forming processes to achieve the required cross-sectional geometry, using simple tools and calenders to control temperature and shape the material, allowing for the production of insulating bars with corrugated structures and accurate connection strips without the need for multiple specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If injection molding is used to manufacture insulating bars with corrugated structures, then the heat insulation properties are improved, but the manufacturing cost and device complexity increase significantly
Solution Approach 1:
The manufacturing process is segmented into two independent stages: first, a planar insulating bar is produced by extrusion; second, the corrugated structure is formed by machining the planar bar. This segmentation allows each stage to use simple, specialized equipment rather than requiring a complex integrated molding system.
Solution Approach 2:
The planar insulating bar is produced in advance by extrusion before the corrugated structure is formed. This preliminary action allows the base structure to be created with simple equipment, and the heat-insulating corrugated features to be added subsequently through machining, avoiding the need for complex integrated molding tools.
2Loss of energy
If injection molding is used to manufacture insulating bars with corrugated structures, then the heat insulation properties are improved, but the manufacturing time and material consumption increase
Solution Approach 1:
The process is divided into extrusion of a planar bar followed by machining of the corrugated structure. While this adds a machining step, it eliminates the lengthy cooling and demolding times associated with injection molding, and allows for continuous production of the planar bars.
Solution Approach 2:
The patent uses a simple extrusion die and machining tools rather than expensive, complex injection molding equipment. The extrusion process is faster and more material-efficient, with minimal waste compared to injection molding which requires sprues, runners, and gate waste.
3Device complexity
If conventional extrusion tools are used to manufacture insulating bars with corrugated structures, then the manufacturing process is simplified, but the dimensional accuracy of connection strips deteriorates
Solution Approach 1:
The tool is segmented into an extrusion die that produces a planar bar with simple geometry, and a separate machining system that forms the corrugated structure. The extrusion die remains simple and easy to manufacture, while the machining system provides the precision needed for the connection strips through controlled material removal.
Solution Approach 2:
The patent replaces the complex mechanical injection molding system with a combination of simple extrusion mechanics and precision machining. The machining process uses controlled material removal to achieve the required dimensional accuracy for connection strips, which is more reliable than trying to achieve it through complex extrusion tooling.
4Shape
If injection molding is used to manufacture long insulating bars, then the corrugated structure can be formed, but the mold filling uniformity and tool cost worsen
Solution Approach 1:
The manufacturing is segmented into extrusion of long planar bars followed by machining of the corrugated structure. The extrusion process can continuously produce long bars with uniform cross-section, and the machining process subsequently adds the corrugated features, avoiding the mold filling problems of injection molding long parts.
5Productivity
If complex extrusion tools are used to produce insulating bars with connection strips, then the production efficiency is improved, but the tool cost and complexity increase
Solution Approach 1:
The production process is segmented into extrusion of planar bars followed by machining of connection strips. The extrusion die remains simple and inexpensive, while the connection strips are efficiently formed by machining the planar bars after extrusion, separating the high-volume production step from the precision-forming step.
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 method reduces production costs and complexity while ensuring dimensional accuracy of the insulating bars, enabling efficient processing into composite profiles with improved heat insulation and mechanical strength, and allows for the simultaneous production of multiple bars with varying geometries.
Implementation Method 1
a band-like extrudate is produced continuously by extrusion or pultrusion of the plastics material
Implementation Method 2
by means of a calender, in particular with the aid of cooling rolls, temperature control is carried out
Implementation Method 3
followed by forming processes to achieve the required cross-sectional geometry
Data Source
AI summary
A method for manufacturing insulating bars made from a thermoplastic material, comprising: producing a band-shaped extrudate having a substantially rectangular cross-section from the thermoplastic material; producing an individual insulating bar or a plurality of insulating bars from the band-shaped extrudate in the longitudinal direction thereof; and severing the insulating bar or bars arrangement in the longitudinal direction thereof to provide separated insulating bars.