Extrusion Die for Reinforcing Bar Polymer Impregnation
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Solution Overview
Problem
Conventional methods for producing reinforcing bars using basalt fibers and thermoplastic polymers require large-scale manufacturing apparatuses and high production costs, making them inconvenient and expensive.
Innovation Solution
A die system comprising a main flow channel and sub flow channels for thermoplastic polymer and fibers, allowing for the impregnation and coating of fibers with polymer in a central and peripheral manner, enabling the production of reinforcing bars with sufficient strength in a more cost-effective and efficient manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the dipping method is used to form the polymer layer around the core material, then the reinforcing bar can be produced with sufficient strength, but the manufacturing apparatus becomes large-scale and production costs increase
Solution Approach 1:
The die is segmented into multiple independent flow channels: a main flow channel for supplying molten polymer and sub-flow channels for supplying reinforcing fibers. These channels are positioned at different locations and feed into a common molding cavity, allowing separate control of polymer and fiber flow paths while achieving uniform impregnation without requiring large-scale dipping equipment
Solution Approach 2:
The invention transitions from the conventional dipping method (where the core is immersed in molten polymer in a storage tank) to a die-based extrusion system. The flow channels are arranged in a multi-dimensional configuration within the die body, with the main flow channel positioned centrally and sub-flow channels positioned peripherally, creating a three-dimensional impregnation structure that eliminates the need for large horizontal storage tanks
2Strength
If the dipping method is used to form the polymer layer, then the reinforcing bar can be produced, but production costs become relatively high
Solution Approach 1:
The invention merges the polymer extrusion process and fiber reinforcement process into a single integrated die system. The molten polymer from the main flow channel and reinforcing fibers from sub-flow channels are combined and impregnated simultaneously in the molding cavity, eliminating the need for separate dipping tanks and reducing overall production costs while maintaining product strength
Solution Approach 2:
The invention changes the physical state and flow parameters of the polymer and fibers. The polymer is heated to a molten state and controlled to flow through the main channel at specific viscosity, while fibers are fed through sub-channels at controlled rates. By optimizing these flow parameters and the timing of material introduction, uniform impregnation is achieved without requiring excessive polymer quantities or complex multi-step processes, thereby reducing production costs
3Strength
If reinforcing fibers are impregnated with thermoplastic polymer in the central portion and polymer covers the outer periphery, then sufficient strength is achieved, but the die structure becomes complex with multiple flow channels
Solution Approach 1:
The die is segmented into functionally distinct flow channels: a centrally positioned main flow channel for polymer supply and peripherally positioned sub-flow channels for fiber supply. This segmentation allows each channel to perform its specific function efficiently while maintaining a relatively simple overall die structure that can be manufactured and assembled from standard components
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 die system allows for the production of reinforcing bars with adequate strength at reduced costs and complexity, eliminating the need for large storage tanks and enabling easier assembly and operation.
Implementation Method 1
a main flow channel (F1), formed in a central portion of a die main body, that serves as a conduit (passageway) for a (molten) thermoplastic polymer (resin) material (Rt) output from an extruder (2)
Data Source
AI summary
A die for molding a reinforcing bar, which enables the production of a reinforcing bar having sufficient strength in a convenient and inexpensive manner, includes: a main flow channel (F1), formed in a central portion of a main body, that receives a molten thermoplastic polymer material (Rt) output from an extruder (2); at least one first sub flow channel (F2), formed in an outer peripheral portion of the main body, that receives the molten thermoplastic polymer material (Rt) and fluidly connects with an outer peripheral portion in the main flow channel (F1); and at least one second sub flow channel (F3) configured to receive reinforcing fibers (4) and fluidly connected with the main flow channel F1 upstream of a junction position of the main flow channel F1 and the at least one first sub flow channel (F2).