Welding Machine for Plastic Profiles with Projecting Faces
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Solution Overview
Problem
Existing machines for welding plastic profiled elements face challenges in effectively machining elements with projecting main faces and in achieving precise movement and suction of plastic material residues, leading to complex machining operations and aesthetic issues in mimicking natural wood joints.
Innovation Solution
A machine designed for welding plastic profiled elements with retaining, displacement, heating, removal, and suction means, featuring a milling tool and suction duct configuration that allows for effective machining and suction despite projecting main faces, enabling precise movement and shaping to create square joints similar to natural wood.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the profiled elements are joined by melting butt portions to create quarter-sawn joints, then the welding strength is improved, but the aesthetic appearance deteriorates compared to natural wood square joints
Solution Approach 1:
The profiled element is divided into two distinct portions: a butt portion for welding and a rib portion for visibility. The butt portion is melted to create the joint, while the rib portion is positioned to be visible after assembly, creating the appearance of a square joint while maintaining the strength of melted welding.
Solution Approach 2:
The profiled elements are designed with asymmetric geometry where one element has a protruding rib portion and the other has a recessed butt portion. This asymmetry allows the visible rib portions to form a square joint appearance while the hidden butt portions are melted together for strength.
2Shape
If the main face of the profiled element is made projecting to achieve square joint appearance, then the aesthetic appearance is improved, but the machining complexity increases due to interference with machine component movement
Solution Approach 1:
The machine components, particularly the suction duct and milling tool, are designed to be movable rather than fixed. This allows them to adapt their position and avoid interference with the projecting main face of the profiled element during machining operations.
Solution Approach 2:
A movable support structure acts as an intermediary between the fixed machine frame and the profiled element. This support can adjust its position to accommodate the projecting main face while still providing stable support for precise machining.
3Productivity
If the suction duct is positioned to effectively suction plastic residues during machining, then the cleaning efficiency is improved, but the positioning becomes complex due to the projecting main face
Solution Approach 1:
The suction duct is designed with movable sections that can adjust their position dynamically during the machining process. This allows the suction openings to be positioned optimally close to the machining area for effective residue removal while avoiding interference with the projecting main face.
Solution Approach 2:
The suction duct is integrated within or alongside the milling tool assembly in a nested configuration. This allows the suction function to be combined with the machining function in a compact arrangement that reduces overall positioning complexity while maintaining cleaning efficiency.
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 machine effectively welds plastic profiled elements with projecting main faces, ensuring precise machining and effective suction of residues, resulting in aesthetically improved joints that mimic natural wood, enhancing the appearance of plastic windows and doors.
Implementation Method 1
heating means adapted to heat the areas to be welded until the plastic material is at least partly melted
Data Source
AI summary
The machine (1) comprises:retaining means (3, 4) of a first profiled element (5) and of a second profiled element (6) made of plastic material, which extend along respective longitudinal directions and are each provided with at least one area to be welded (7) substantially inclined by an angle comprised between 10° and 80° with respect to the respective longitudinal direction and at least one main face (5a, 6a) square-shaped, wherein the main face (5a) of the first profiled element (5) is projected with respect to the respective area to be welded (7) and the main face (6a) of the second profiled element (6) is recessed with respect to the relevant area to be welded (7);removal means (16) comprising a pair of milling tools (17) movable in rotation around a relevant axis of rotation (R);suction means (20) adapted to remove the residues of plastic material generated during the removal of the plastic material;wherein the suction means (20) comprise at least one suction duct (21) arranged around a respective milling tool (17), which comprises a substantially flat abutment portion (24) adapted to internally abut against the main face (5a) of the first profiled element (5) during the removal of the plastic material.