Linear Bearing Array for Die Lip Gap Adjustment
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Solution Overview
Problem
Existing die adjustment mechanisms for extrusion dies fail to provide bi-directional, quick, accurate, and repeatable adjustments of the gap between lips of adjacent die bodies, particularly for wide dies, and struggle to maintain a uniform gap across the die width.
Innovation Solution
A die adjustment system incorporating a cross-bar, linear moving members, slide fasteners, pivoting members, and linear bearings, allowing for single-point adjustment of the gap between flexible lips of die bodies, enabling precise and repeatable control of the lip gap through a combination of sliding and pivoting mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional link mechanisms are used to adjust the flexible lip, then the die can be adjusted, but the adjustment process is slow and requires significant force
Solution Approach 1:
The patent replaces the traditional mechanical link system with a cam mechanism that converts rotational motion into linear displacement of the flexible lip. The cam profile is specifically designed to provide the desired lip movement characteristics, eliminating the need for complex linkages and reducing adjustment time significantly.
Solution Approach 2:
The patent introduces a dynamic adjustment mechanism where the cam can be rotated to different positions to achieve various lip gap settings. This dynamic system allows for quick adjustments by simply rotating the cam to a new position rather than manually manipulating multiple links.
2Manufacturing precision
If traditional adjustment mechanisms are used, then the die structure remains simple, but the gap uniformity across wide dies cannot be maintained
Solution Approach 1:
The patent divides the adjustment mechanism into multiple independent cam units, each responsible for a specific section of the flexible lip. This segmentation allows for localized adjustment of different portions of the lip, enabling precise control of gap uniformity across wide dies while keeping each individual cam unit relatively simple.
Solution Approach 2:
The cam mechanism serves multiple functions: it provides the primary lip gap adjustment, maintains gap uniformity across the die width, and can be designed to accommodate different die widths by simply adding or removing cam units. This multi-functionality reduces the need for entirely different mechanisms for different die sizes.
3Adaptability or versatility
If multiple links and adjustment bars are used, then the adjustment range is increased, but the mechanism becomes more complex and harder to control
Solution Approach 1:
The patent transitions from linear adjustment (moving links along a bar) to rotational adjustment (rotating the cam). This dimensional change allows for a compact mechanism that provides a wide adjustment range through the full rotation or partial rotation of the cam, eliminating the need for long adjustment bars and multiple links.
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 system allows for efficient, accurate, and repeatable adjustment of the lip gap, reducing the force required for adjustment and maintaining uniformity across the die width, enhancing the precision and efficiency of extrusion processes while accommodating a wide range of lip gap dimensions.
Implementation Method 1
Use of the linear bearings, especially in conjunction with the pivoting members, cross-bar and linear moving members noted herein provides for exceptional and unexpected ease in making adjustments to the lip
Data Source
AI summary
A die apparatus including a flexible lip integrally connected to a main body, the lip configured to adjust a gap between the flexible lip and a second lip and includes a slide bar equipped with multiple linear bearings where the slide bar and bearings are positioned in a slot of the main body, the multiple bearings further positioned in multiple pockets defined by the slide bar, the slot positioned in a spaced relation from the lip. In one aspect the slide bar includes a threaded hole to receive a fastener configured to fasten a pivot member to the slide bar, the pivot member configured to pivot in order to adjust the lip. The slide bar and bearings may be used on a variety of die apparatus having an integrally connected lip.