Thermoplastic Board Lamination for Variable Waste Extrusion Flow
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Solution Overview
Problem
Existing polymer lamination processes are inefficient in handling typical oscillations in waste extrusion flow indices, leading to inconsistent product formation and limited thickness and width capabilities.
Innovation Solution
A high-pressure extrusion and diffusion system combined with a multiple laminating process using cool pressing plates and molecular fixation, along with a lamination system that absorbs volumetric variations, allows for the production of thermoplastic boards with enhanced thickness and width, and includes additional finishing options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If classical extrusion processes are used for polymer lamination, then the process is simple to operate, but the product formation is inconsistent due to oscillations in waste extrusion flow indices and the thickness and width capabilities are limited
Solution Approach 1:
The patent divides the lamination process into multiple sequential laminating stages (first laminating means, second laminating means, etc.), where each stage progressively reduces thickness and consolidates the product. This segmentation allows better control over volumetric variations and flow index oscillations, improving product formation consistency while managing complexity through modular process design
Solution Approach 2:
The patent incorporates preliminary mixing and pre-lamination stages before final consolidation, where materials are pre-conditioned and partially consolidated to reduce subsequent processing variations. This preliminary action stabilizes the material properties before entering the main lamination sequence, reducing oscillations in product formation
2Length of stationary object
If high pressure and multiple laminating processes are used, then thickness and width capabilities are enhanced, but the device complexity increases
Solution Approach 1:
The patent extends the lamination process from single-stage to multi-stage sequential processing, adding temporal and spatial dimensions to the consolidation process. Multiple laminating means operate in sequence, each contributing to progressive thickness reduction and width stabilization, enabling enhanced dimensional capabilities through cumulative effect rather than single high-complexity unit
Solution Approach 2:
The patent employs dynamic adjustment of processing parameters (temperature, pressure, speed) across different lamination stages, allowing the system to adapt to material variations and optimize consolidation at each phase. This dynamic control enables enhanced product dimensions while managing system complexity through flexible parameter adjustment rather than fixed complex hardware
3Manufacturing precision
If multiple laminating stages are used to reduce volumetric variations, then product uniformity is improved, but the processing time increases
Solution Approach 1:
The patent implements continuous multi-stage lamination where material flows sequentially through multiple consolidating stages without interruption or re-positioning. Each laminating stage operates continuously on the moving web, maintaining productive action throughout the process. This continuous multi-stage approach achieves better uniformity than batch processing while minimizing idle time between stages
Solution Approach 2:
The patent employs periodic consolidation cycles within the multi-stage process, where alternating stages apply different levels of pressure and temperature to progressively consolidate the material. This periodic variation in processing intensity optimizes densification at each stage while maintaining overall process efficiency and reducing total processing time compared to uniform continuous pressing
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 process achieves uniform product formation with improved thickness and width capabilities, up to 200 mm and 6,000 mm respectively, while minimizing density variations and enabling surface finishing techniques.
Implementation Method 1
The thermoplastic plate production process uses an extruder (1) with temperatures from 100 to 450° C., which delivers a large volume of plastic mass
Implementation Method 2
Plastification/gelling/melting of the mass
Implementation Method 3
where the already laminated plastic mass passes to molecular fixing line (3), through cool pressing plates
Implementation Method 4
through cool pressing plates, passing to the cutting line (4)
Implementation Method 5
A high-pressure extrusion and diffusion system combined with a multiple laminating process
Data Source
AI summary
The present disclosure relates to the process of producing thermoplastic, smooth and/or corrugated tile type board, based on new polymers or polymeric waste, pure and or composed of various plastics, whether or not chemically compatible, with or without fillers, natural/industrial/mineral/animal, individually and/or combined up to 80% by lamination process, in single or multilayer form, using various melting process mechanisms; and also allowing the interlayer and/or superficial introduction of bodies, rigid or flexible, for the purpose of structural reinforcement and or surface finishing, characterized by using an extruder that delivers a large volume of plastic mass to the lamination line, where the already laminated plastic mass passes to the molecular fixing line, through cool pressing plates, moving into to the cutting line, through the side cutting and dividing saw, being the product sent to completion section, through the square cutting and deposition on distribution table.