Post-Extrusion Filling and Closure of Extrudates
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Solution Overview
Problem
Current extrusion technology faces limitations in coextruding granular or particulate materials due to the restricted orifice size of extrusion dies, making it difficult to incorporate such materials internally within the extruded product.
Innovation Solution
An apparatus and method for post-extrusion filling and closing of extrudates, which involves a feeder to deposit filler materials into the extruded rope of material as it flows from the extruder and a former to shape and seal the material around the filler, creating an opening for internal filling and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional extrusion die with restricted orifice size is used, then the extrusion process is simple, but granular or particulate materials cannot be included internally within the extruded product
Solution Approach 1:
The extrusion process is divided into two separate stages: first, the extruder forms a hollow rope or tube structure; second, a separate filler device introduces granular materials into the hollow interior. This segmentation allows each device to be optimized for its specific function, enabling granular material inclusion without requiring complex modification of the extrusion die itself.
Solution Approach 2:
The invention transitions from attempting to include granular materials during the horizontal extrusion process to introducing them vertically into the hollow interior of the extruded rope. This dimensional change allows granular materials to be incorporated without interfering with the extrusion flow, effectively bypassing the orifice size limitation.
2Adaptability or versatility
If larger orifice size is used to accommodate granular materials, then granular materials can be coextruded, but the precision and control of extrusion process deteriorates
Solution Approach 1:
By separating the extrusion function from the filling function, the system maintains precise control over the extrusion process through the original die design while using a separate mechanism for granular material introduction. This avoids the need to enlarge the extrusion die orifice, thereby preserving manufacturing precision.
Solution Approach 2:
The hollow rope structure acts as an intermediary carrier that receives granular materials after extrusion. This mediator allows granular materials to be incorporated without directly interacting with the extrusion die, maintaining precision control while achieving coextrusion capability.
3Adaptability or versatility
If post-extrusion filling is implemented, then granular materials can be included internally, but the device complexity increases
Solution Approach 1:
The filler device is designed to work with various types of extruded ropes and different granular materials, making it a universal solution. The device can handle different material viscosities, particle sizes, and rope dimensions, reducing the need for multiple specialized devices and justifying the added complexity through broad applicability.
Solution Approach 2:
The filler device is positioned to receive extruded ropes and nest the granular materials within the hollow interior of the rope. This nested arrangement allows compact integration of the filling function alongside the extrusion process without requiring excessive space or complex mechanical linkages.
Data Source
AI summary
An apparatus and method for post-extrusion filling and closing of an extrudate includes a feeder arranged in relation to an extruded rope of material flowing from an extrusion die of an extruder, wherein the rope of material has an opening that can receive a filler material. The feeder deposits the filler material into the opening of the rope of material as the rope of material flows by the feeder. A former receives the rope of material after the feeder has deposited the filler material into the opening of the rope. The former shapes the rope of material and close a portion or all of the rope around at least a portion of the deposited filler material to retain the filler material within the rope. A cutter may axially cut the rope to form the opening. A finisher may cut the shaped rope into portions containing the deposited filler material.