Profiled Part Welding Device with Movable Molded Part
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Solution Overview
Problem
Existing methods for connecting plastic profile parts, such as PVC profile bars to window frames, often result in uncontrollable melt deformation and the formation of visible weld beads, requiring post-processing removal, which can damage the profiles and is inefficient.
Innovation Solution
A device and method where the processing tool, with a movable molded part forming an angle of 10° to 50° with the profile support, moves obliquely or diagonally to control the melt flow and deformation, eliminating the need for post-processing by shaping and controlling the melted plastic during the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed limiting element is used to control melt flow during welding, then the melt flow is restricted, but visible weld beads form on the visible surfaces requiring post-processing removal
Solution Approach 1:
The limiting element is designed to be movable rather than fixed, allowing it to adapt its position during the welding process. The element can move in the longitudinal direction of the profile part to dynamically control melt flow, preventing excessive melt from reaching visible surfaces while maintaining effective restriction where needed.
Solution Approach 2:
The movable limiting element acts as an intermediary between the heating element and the profile part, providing controlled restriction of melt flow. It mediates the interaction by being positioned between the heat source and the profile, allowing precise control over where melt is restricted and where it can flow naturally.
2Manufacturing precision
If post-processing removal of weld beads is performed, then visible surfaces are cleaned, but the profiles are damaged and the process is inefficient
Solution Approach 1:
The movable limiting element prevents the formation of excessive weld beads in the first place by controlling melt flow during welding. By applying preliminary restriction at the source, it prevents the harmful effect (visible weld beads) from occurring, eliminating the need for subsequent removal operations.
Solution Approach 2:
The limiting element is positioned and configured before welding begins to pre-establish the desired melt flow paths. This preliminary arrangement ensures that melt is directed away from visible surfaces during the welding process itself, preventing the need for post-processing intervention.
3Manufacturing precision
If the limiting element is adjusted to a tight fit, then melt flow is better controlled, but the gap for melt flow is reduced requiring higher processing force
Solution Approach 1:
The limiting element can dynamically adjust its position and fit during the welding process. It can be positioned closer to the profile for tight control where needed, and moved away where melt flow is acceptable, optimizing the balance between control precision and force requirements in different zones.
Solution Approach 2:
Different sections of the limiting element can have different degrees of restriction. The element can provide tight fit in areas where precise melt flow control is critical, while allowing more generous gaps in areas where melt flow is less critical, creating locally optimized control throughout the welding zone.
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
This approach prevents damage to the profiles, eliminates visible weld beads, and reduces the force required for processing, achieving a stronger and more aesthetically pleasing welded joint with improved temperature distribution and strength at corners.
Implementation Method 1
the connecting surfaces are then pressed against the heating element in a joining direction for the so-called alignment and preheating process, melting material at the joining surface
Implementation Method 2
The connecting surfaces are then pressed against the heating element in a joining direction for the so-called alignment and preheating process
Implementation Method 3
During the actual melting process, the PVC begins to flow and deform, moving inwards into the profile chambers and outwards onto the visible surfaces of the PVC profile
Implementation Method 4
the PVC begins to flow and deform
Implementation Method 5
a processing tool with which the flow and deformation of the molten material can be controlled
Implementation Method 6
the molded part is moved from a rest position towards a working position relative to the profile support receptacle
Implementation Method 7
the still-hot, thermoplastic material of the two profile bar ends fuses together to create a stable weld
Implementation Method 8
the still-hot, thermoplastic material of the two profile bar ends fuses together
Data Source
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AI summary
The invention relates to a device (1) for connecting profiled parts (12) to profile supports which are arranged perpendicularly to one another and which have profile support receiving areas (2) for receiving and clamping the profiled parts (12). At least one profiled part (12) and a heating surface of a heating element of the device (1) can be brought into contact with each other in order to melt the at least one profiled part (12) in the profiled part welding region prior to joining with the other profiled part. A machining tool (3) is provided which has at least one molding part (4), by means of which a flow and deformation of a melt product on a visible surface of a profiled part (12) can be controlled. The aim of the invention is to provide an improved device (1) for connecting profiled plastic parts, said device preventing the aforementioned disadvantages while simultaneously configuring the discharge of the melt in a controllable manner such that a post-machining process can be completely or at least partly omitted. According to the invention, this is achieved in that the molding part (4) and the profile support receiving areas (2) form an angle (5) between 10° and 50° relative to each other, and the molding part (4) can be moved from a rest position in the direction of a working position relative to the profile support receiving area (2).