Profiled Part With Multi-Layer Extrusion For High-Pressure Forming
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Solution Overview
Problem
Existing methods for producing endless profiles are not suitable for internal high-pressure forming and overmoulding due to insufficient stability, often resulting in air pockets and quality issues, and involve multi-stage discontinuous processes.
Innovation Solution
A profile part with an extruded inner profile and a reinforcement layer made of fiber-reinforced plastic, applied in a continuous process, providing stability for high-pressure forming and overmoulding, and eliminating air pockets by integrating the layers for improved quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous profile is produced by coating reinforcing fiber-containing roving with a plastic layer in a multi-stage discontinuous process, then the production process can be implemented with existing equipment, but the profile lacks sufficient stability to withstand internal high-pressure forming and overmolding due to the multi-stage process introducing air inclusions
Solution Approach 1:
The patent combines the production of the reinforcing layer and the surrounding plastic layer into a single continuous extrusion process, eliminating the multi-stage discontinuous process. This merging of operations prevents air inclusions and ensures the profile has sufficient stability for internal high-pressure forming and overmolding, while maintaining production feasibility with existing equipment.
2Reliability
If a single-layer plastic coating is applied to the reinforcing layer, then the production process is simpler, but the profile lacks sufficient stability for internal high-pressure forming and overmolding
Solution Approach 1:
The patent segments the plastic layer into multiple layers with different functions: an inner layer in direct contact with the reinforcing fibers and an outer layer providing additional stability. This segmentation allows each layer to be optimized for its specific function while maintaining a relatively simple continuous extrusion manufacturing process, ensuring the profile has sufficient stability for internal high-pressure forming and overmolding.
3Manufacturing precision
If the reinforcing layer is produced separately and then covered with plastic layer in a separate step, then each layer can be optimized independently, but air inclusions are formed that impair stability and quality
Solution Approach 1:
The patent merges the production of the reinforcing layer and the plastic layer into a single continuous extrusion process where both layers are formed simultaneously. This eliminates the separation step that introduces air inclusions, ensuring high manufacturing precision and quality while preventing the formation of harmful air pockets that would impair profile stability.
4Strength
If a multi-layer inner profile structure is used, then the profile can withstand internal high-pressure forming and overmolding, but the manufacturing process becomes more complex
Solution Approach 1:
The patent segments the inner profile into multiple layers with different materials and functions, where each layer contributes to the overall strength and stability required for internal high-pressure forming and overmolding. Despite this segmentation, the multi-layer structure is produced through a continuous extrusion process that, while requiring multiple extruders, maintains operational simplicity through integration and simultaneous production, avoiding the need for separate assembly steps.
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 enables the production of a stable profile part suitable for internal high-pressure forming and overmoulding, with increased quality and reduced defects, using a multi-layer structure that can be tailored for specific applications, and is recyclable.
Implementation Method 1
the inner profile can be given sufficient stability for an internal high-pressure forming process and/or overmolding with a thermoplastic material
Implementation Method 2
The inner profile is designed to consist of at least two layers and to be formed as an extrusion profile
Data Source
Figure 1~2
AI summary
The invention relates to a profiled part (1) comprising an inner profile (3), which is designed as an extrusion profile, and at least one reinforcing layer (5), which consists of a fiber-reinforced plastic material and is applied to the inner profile (3), characterized in that the inner profile (3) is constituted of at least two layers.