Modular Extrusion Nozzle with Interchangeable Air Inserts
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Solution Overview
Problem
Existing extrusion nozzles face challenges in reproducibly and flexibly adjusting air flow to optimize profile quality, particularly in adapting to different profile geometries and extrusion line modifications, leading to inefficiencies and potential production stoppages due to the difficulty in reconfiguring air outlet nozzles without dismantling the extrusion line.
Innovation Solution
A modular extrusion nozzle design with standardized recesses for interchangeable air nozzle inserts, allowing for flexible and reproducible air supply to specific areas of the profile, featuring multiple air supply openings and a distribution chamber with adjustable air outlet nozzles that can be directed at various angles, enabling precise control over air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If air outlet nozzles are machined directly into the nozzle plate, then the air flow can be applied to the profile surface, but the adjustment of flow velocity, impact angle, and precise impact position cannot be easily and flexibly adjusted
Solution Approach 1:
The nozzle system is segmented into a fixed nozzle plate and interchangeable nozzle inserts. Each insert contains air outlet nozzles that can be independently adjusted and replaced, allowing flexible modification of air flow parameters without redesigning the entire nozzle plate structure.
Solution Approach 2:
The nozzle inserts are designed to be movable and adjustable within the nozzle plate, enabling dynamic adjustment of air flow velocity, impact angle, and impact position. This allows the system to adapt to different profile geometries and extrusion conditions while maintaining a relatively simple overall structure.
2Manufacturing precision
If the extrusion die is completely disassembled to realign air outlet nozzles, then the air flow can be optimized for profile quality, but the extrusion line must be shut down and reconfiguration time increases
Solution Approach 1:
By separating the nozzle inserts from the main extrusion die assembly, the system allows independent adjustment of air flow parameters without requiring complete disassembly of the extrusion line. This maintains production continuity while achieving optimized profile quality.
Solution Approach 2:
The system enables rapid adjustment of air flow parameters (velocity, angle, position) by simply changing nozzle inserts rather than reconfiguring the entire extrusion die. This allows optimization of profile quality through parameter modification without significant production interruption.
3Adaptability or versatility
If the nozzle body is moved to adapt to different profile geometries, then some flexibility is achieved, but the impact angle cannot be adjusted and exact position determination is uncertain
Solution Approach 1:
The nozzle system is divided into adjustable nozzle inserts that can be independently positioned and angled within standardized recesses in the nozzle plate. This segmentation enables precise control of both position and impact angle for different profile geometries.
Solution Approach 2:
The nozzle inserts incorporate adjustable mechanisms that allow dynamic modification of both the position and impact angle of air outlets. This provides precise and reproducible adjustment capabilities adapted to various profile geometries, overcoming the limitations of fixed or simply movable nozzle bodies.
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
Enables flexible and reproducible optimization of profile quality by allowing easy reconfiguration of air flow patterns without disrupting the extrusion process, improving surface quality and reducing the risk of profile sticking during calibration.
Implementation Method 1
Blowing cold or hot air reduces the friction of the melt against the calibrator wall (with cold blow air), the tensile strength of the profile segment by cooling the surface layer (with cold blow air), and the swelling of the melt in the transition zone (with hot blow air).
Implementation Method 2
The hot blow air causes the particularly high residual stresses present in the surface layer of the melt to relax more quickly, thus reducing swelling.
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to an extrusion die for producing a plastic profile, comprising a first die plate (1) which has a flow channel for the plastic profile to be produced. According to the invention, the first die plate (1) has at least one recess for receiving replaceable air nozzle inserts (6), which have an air channel with at least one air outlet nozzle (9), wherein at least one air supply bore (11) leads from a connection on the outside of the first die plate (1) into each recess.