Wetted Calibrator Convection Cooling Window Frame Extrusion
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Solution Overview
Problem
The conventional dry calibrator used in window frame manufacturing has an insufficient cooling effect due to conduction cooling, leading to a low extrusion linear speed, which hinders competitiveness in the manufacturing process.
Innovation Solution
A wetted type calibrator is introduced, featuring a housing with a calibrator assembly comprising multiple disk parts and water discharge holes, utilizing convection cooling to cool the surface of the extruded synthetic resin product first, followed by cooling the inner portion, enhancing the cooling effect with an intensive cooling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dry calibrator with conduction cooling is used, then the structure is simple, but the cooling effect is insufficient and extrusion linear speed is low
Solution Approach 1:
The patent applies hydraulic cooling by introducing water into the calibrator through water introduction holes formed in the calibrator body. The water flows through channels within the calibrator structure, directly contacting the extruded product to remove heat through convection and conduction, thereby significantly improving cooling efficiency and enabling higher extrusion speeds
Solution Approach 2:
The patent changes the thermal cooling parameters by transitioning from air cooling to water cooling. The water temperature, flow rate, and distribution patterns are optimized to achieve superior heat removal efficiency, allowing the extrusion process to operate at higher speeds while maintaining product quality
2Temperature
If water cooling is introduced into the calibrator, then the cooling effect is enhanced, but the device complexity increases
Solution Approach 1:
The patent merges the cooling function directly into the calibrator structure by integrating water channels and cooling elements within the calibrator body. This combination eliminates the need for separate external cooling systems, reducing overall system complexity while achieving effective water cooling of the extruded product
Solution Approach 2:
The patent utilizes a porous cooling structure where water is introduced through holes and channels formed within the calibrator material. This porous approach allows uniform water distribution and efficient heat transfer from the extruded product to the cooling water, enhancing cooling effectiveness
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 wetted type calibrator significantly improves the extrusion linear speed from 2.5 m/min to 3.5 m/min and enhances the cooling effect by using convection cooling, effectively addressing the limitations of the dry calibrator's conduction cooling method.
Implementation Method 1
utilizing convection cooling to cool the surface of the extruded synthetic resin product first, followed by cooling the inner portion, enhancing the cooling effect
Implementation Method 2
an intensive cooling system having the wetted type calibrator including multiple disk parts is disposed at a next process of an extrusion molding process so as to enhance cooling effect
Data Source
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AI summary
Disclosed is a wetted type calibrator for manufacturing a window frame and a manufactruing device including the same, in which an intensive cooling system having the wetted type calibrator including multiple disk parts is disposed at a next process of an extrusion molding process so as to enhance cooling effect. The wetted type calibrator for manufacturing the window frame includes a houwing which accommdates a desired amount of water therein; and a calibrator assembly which is disposed in the housing so that an extruded product formed of a synthetic resin material is passed therethrough. The apparatus for manufacturing the window frame includes an extruder in which functions to a raw mater injected through a hopper is heated and melted in a heating cylinder having a heater and then the melted material is extruded by rotation of a screw; an extrusion die by which the gel-state material supplied through the extruder is formed into a desired shape; a wetted type calibrator which forms a profile shape of the product passed through the extrusion die and also forms the product having a precise dimension and shape; a water tank which cools the extruded product passed through the wetted type calibrator; an extracting device which pulls the extruded product passed through the water tank with constant foce; and a cutting device which cuts the extruded product in a desired size.