Intersecting Flow Plate for Fiber-Randomizing Extrusion
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Solution Overview
Problem
Highly filled composite materials with high-aspect-ratio fibers tend to align fibers in the flow direction during extrusion, resulting in anisotropic materials, which lack uniform mechanical properties in all directions.
Innovation Solution
A fluid-flow-modification plate with intersecting passages that randomize the orientation of reinforcing fibers during extrusion, producing an isotropic material by redirecting and intertwining fluid streams within an extruder system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If highly filled composite materials are extruded through a conventional extrusion die, then the extrusion process is simple and efficient, but the fibers align in the flow direction resulting in anisotropic material properties
Solution Approach 1:
The extrusion die is segmented into multiple passages (first, second, third, and fourth passages) that divide the fluid flow into separate streams. These segmented flows then intersect and mix within the die, randomizing fiber orientation while maintaining high extrusion efficiency through the modular passage structure
Solution Approach 2:
The invention introduces a new dimensional aspect to fiber orientation by creating intersecting three-dimensional passages that redirect fluid streams in multiple directions. The passages are configured to intersect at specific boundaries, creating complex flow patterns that randomize fibers in three-dimensional space rather than simple linear flow
2Stability of the object's composition
If passages are configured to intersect within the extrusion die, then fiber orientation is randomized improving material isotropy, but the device structure becomes more complex
Solution Approach 1:
Multiple fluid passages are merged and configured to intersect within a single integrated extrusion die structure. The first, second, third, and fourth passages are combined in one component with defined intersection boundaries, achieving fiber randomization without requiring multiple separate components or complex assembly
Solution Approach 2:
The extrusion die performs multiple functions simultaneously: it divides the fluid flow into separate passages, redirects the flows in different directions, creates intersecting flow patterns for fiber randomization, and maintains structural integrity as a single component. This multi-functionality reduces the need for additional separate devices
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 solution effectively randomizes fiber orientations, resulting in materials with consistent mechanical properties in all directions, enhancing structural integrity and performance.
Implementation Method 1
A fluid-flow-modification plate with intersecting passages that randomize the orientation of reinforcing fibers during extrusion, producing an isotropic material by redirecting and intertwining fluid streams within an extruder system
Data Source
Figure 1A-1
Figure 1A-2
Figure 1B-1
AI summary
A fluid-flow-modification plate (200) comprises a monolithic body (300), having an inlet-side surface (301), an outlet-side surface (302), a first passage (501), a second passage (502), a third passage (503), and a fourth passage (504). The first passage (501), second passage (502), third passage (503), and fourth passage (504) each extend between the inlet-side surface (301) and the outlet-side surface (302). The first passage (501) and second passage (502) intersect each other at a first intersection boundary (530). The third passage (503) and fourth passage (504) intersect each other at a second intersection boundary (531). The first passage (501) and third passage (503) do not intersect each other. The first passage (501) and fourth passage (504) do not intersect each other. The second passage (502) and third passage (503) do not intersect each other. The second passage (502) and fourth passage (504) do not intersect each other. The first-passage-inlet-opening perimeter boundary (311) has single-point contact with the fourth-passage-inlet-opening perimeter boundary (314). The second-passage-outlet-opening perimeter boundary (412) has single-point contact with the third-passage-outlet-opening perimeter boundary (413).