WO2015039929A1 - A method to control the amount of polymer material in an extrusion process - Google Patents

A method to control the amount of polymer material in an extrusion process Download PDF

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Publication number
WO2015039929A1
WO2015039929A1 PCT/EP2014/069204 EP2014069204W WO2015039929A1 WO 2015039929 A1 WO2015039929 A1 WO 2015039929A1 EP 2014069204 W EP2014069204 W EP 2014069204W WO 2015039929 A1 WO2015039929 A1 WO 2015039929A1
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WO
WIPO (PCT)
Prior art keywords
polymer material
overflow
extrusion head
thickness
metal element
Prior art date
Application number
PCT/EP2014/069204
Other languages
French (fr)
Inventor
Gerdy BONTE
Original Assignee
Nv Bekaert Sa
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Filing date
Publication date
Application filed by Nv Bekaert Sa filed Critical Nv Bekaert Sa
Publication of WO2015039929A1 publication Critical patent/WO2015039929A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/146—Controlling the extrusion apparatus dependent on the capacitance or the thickness of the insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/06—Rod-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/27—Cleaning; Purging; Avoiding contamination
    • B29C48/272—Cleaning; Purging; Avoiding contamination of dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92323—Location or phase of measurement
    • B29C2948/92361—Extrusion unit
    • B29C2948/92409—Die; Nozzle zone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92514—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/9258—Velocity
    • B29C2948/9259—Angular velocity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92609—Dimensions
    • B29C2948/92619—Diameter or circumference
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92609—Dimensions
    • B29C2948/92647—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92695—Viscosity; Melt flow index [MFI]; Molecular weight
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92819—Location or phase of control
    • B29C2948/92857—Extrusion unit
    • B29C2948/92876—Feeding, melting, plasticising or pumping zones, e.g. the melt itself
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/27—Cleaning; Purging; Avoiding contamination
    • B29C48/274—Cleaning; Purging; Avoiding contamination of the extruded articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
    • B29C48/2883—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules of preformed parts, e.g. inserts fed and transported generally uninfluenced through the extruder or inserts fed directly to the die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/34—Cross-head annular extrusion nozzles, i.e. for simultaneously receiving moulding material and the preform to be coated

Definitions

  • the invention relates to a method to control the amount of overflow
  • the invention further relates to an equipment to control the amount of overflow polymer material created at the entrance side of an extrusion head.
  • the elongated metal element such as the metal wire passes through an extrusion head fed with molten polymer from the extruder.
  • the die or the last die in case a number of dies is used) in the extrusion head determines the final diameter of the coated product.
  • the final quality of the coated product is for example checked by an automatic diameter control.
  • a method to control the amount of polymer material in an extrusion process is provided. The method comprises the steps of
  • predetermined maximum value increasing or decreasing the amount of polymer material to be extruded present in said extruder to restore said thickness of said overflow polymer material in said range defined by said predetermined minimum value and said predetermined maximum value.
  • the polymer coating is extruded in the extruder under pressure.
  • the overflow material is bulging outward from the extrusion head at the entrance side of the extrusion head.
  • the overflow polymer material has preferably a convex shape.
  • axis Y is different from axis X.
  • the axis Y is different from axis X.
  • inclined angle between axis Y and axis X is ranging between 5 and 90 degrees, for example between 30 and 70 degrees, such as 40 degrees, 45 degrees of 50 degrees.
  • extruder can be influenced by
  • the extrusion process can be influenced by a combination of parameters.
  • the amount of polymer material in the extrusion process is controlled by monitoring the amount of polymer overflow material.
  • the amount is corrected by increasing or decreasing the amount of polymer material to be extruded in the extruder. Controlling the extrusion process by monitoring the amount of polymer overflow material according to the present invention has several advantages :
  • the extruded coating has a constant thickness while no polymer material is wasted. There is no need to provide tools to remove excess material, such as tools to blow of excess material.
  • the elongated metal element comprises preferably a metal wire or a metal cord, for example a steel wire or a steel cord.
  • the elongated metal element may have any type of cross-section.
  • the elongated metal element has a circular cross-section or a flattened cross-section, for example a rectangular or substantially rectangular cross-section.
  • diameter of the elongated metal element ranges preferably between 0.8 and 10 mm, more preferably between 1 and 8 mm, for example 2, 4 or 6 mm.
  • the elongated metal element has a flattened cross-section
  • the elongated metal element has preferably a width ranging between 2 and 15 mm, more preferably between 2.4 and 9.2 mm.
  • the thickness ranges preferably between 0.5 and 1 .5 mm, more preferably between 0.8 and 1 .25 mm.
  • the elongated metal element such as the steel wire is provided with a zinc or a zinc alloy coating.
  • the zinc alloy layer preferably comprises between 2 and 15 % aluminium (Al). Possibly, the zinc alloy coating further comprises between 0.1 and [0016]
  • the zinc or zinc alloy layer can be applied by any conventional technique such as chemical plating, melt plating, melt spraying and electroplating. A preferred method to apply the zinc alloy layer is by hot dip.
  • the polymer material may comprise any type of thermoplastic material.
  • the polymer material comprises polyester.
  • Suitable polyester coatings are polyethylene terephthalate (PET), polyethylene naphthalate (PEN) and polybutylene therephthalate (PBT).
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • PBT polybutylene therephthalate
  • polyethylene terephthalate polyethylene naphthalate
  • polybutylene therepthalate denote not only
  • the polymer may also contain mixtures of polymer in order to modify certain of the properties.
  • the thickness of the polymer material on the elongated metal element ranges preferably between 15 ⁇ and 250 ⁇ , more preferably between 30 ⁇ and 150 ⁇ .
  • the material at the entrance side of said extrusion head is monitored.
  • the monitoring is done by measuring the thickness of the overflow polymer material.
  • a preferred method to measure the thickness of the overflow polymer material is by means of an optical device such as a laser beam.
  • the thickness of the overflow polymer material is preferably measured by projecting a laser beam on the overflow polymer material at the entrance side of the extrusion head. Subsequently, the laser beam is reflected by the overflow polymer material to a laser sensor.
  • a thickness of the overflow polymer material is determined. Subsequently, the thus obtained value of the thickness of the overflow polymer material is compared with a
  • predetermined minimum and maximum value In case the measured thickness is outside the range determined by the predetermined minimum and maximum value, the amount of polymer material to be extruded present in the extruder is increased or decreased so that the thickness of the overflow polymer material at the entrance side of the extrusion head is in the range determined by the predetermined minimum and maximum value.
  • an equipment to control the amount of polymer material in an extrusion process comprises
  • extruder comprising an extrusion head, said extrusion head having an entrance side and an exit side;
  • predetermined minimum value and a predetermined maximum value.
  • the extrusion head defines an axis X.
  • the elongated metal element is introduced in the extrusion head along axis X.
  • the thickness of the overflow material is measured along an axis Y.
  • Axis Y is different form axis X.
  • the device to monitor the thickness of overflow polymer material at the entrance side of an extrusion head comprises a laser.
  • the means to control the extrusion process comprise for example - means to increase or decrease the amount of polymer material added to the extruder;
  • FIG. 1 is a schematic illustration of an extrusion installation
  • FIG. 2 is a schematic illustration of the extrusion head provided with a device to monitor the thickness of overflow polymer material at the entrance side of an extrusion head.
  • Figure 1 shows an equipment 100 comprising an extruder 102.
  • extruder 102 comprises a hopper 104, an extrusion screw (not shown) and an extrusion head 108.
  • the hopper 104 feeds material, for example granular material, into the extrusion screw where the material is heated and compressed into a fluent plastic material that is forced through the extrusion head 108 where the fluent plastic material is coated around the wire 1 10 that is being pulled through the extrusion head 108.
  • Wire 1 10 is entering the extrusion head 108 along axis X at the entrance side 1 12 and coated wire 1 10' is leaving the extrusion head 108 at the exit side 1 14.
  • overflow polymer material or excess polymer material 1 16 is accumulated at the entrance side 1 12 of the extrusion head 108.
  • the extrusion line can further be provided with a device to take off the wire 1 10, a device to take up the coated wire 1 10', one or more cooling units, one or more heating units, one or more curing units, one or more cleaning units, one or more quality control devices, ...
  • Figure 2 shows a schematic illustration of the cross-section of the extrusion head 108 shown in Figure 1 including the wire 1 10 passing through the extrusion head 108.
  • the die 1 18 determines the final diameter of the coated wire 1 10'.
  • the extrusion head 108 is provided with a device 120 to monitor the thickness of the polymer overflow polymer material 1 16 at the entrance side 1 12 of the extrusion head 108.
  • the thickness of the overflow polymer material 1 16 is determined along axis Y.
  • the device 120 comprises for example a laser.
  • a laser beam 122 is projected on the overflow polymer material 1 16 at the entrance side 1 12 of the extrusion head 108.
  • the laser beam 122 is reflected by the polymer overflow polymer material 1 16 to a laser sensor 124. Possibly, the laser sensor 124 is integrated in device 120. From the reflected laser beam 122', a thickness of the overflow polymer material 1 16 is determined.
  • the thus obtained value of the thickness of the overflow polymer material 1 16 is compared with a predetermined minimum value 126 and a predetermined maximum value 128.
  • a predetermined minimum value 126 and a predetermined maximum value 128 In case the measured thickness is outside the range determined by the predetermined minimum value 126 and the predetermined maximum value 128, one or more parameters of the extrusion process are influenced so that the thickness of the polymer overflow polymer material at the entrance side of the extrusion head is in the range determined by the predetermined minimum value 126 and the predetermined maximum value 128.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

The invention relates to a method and equipment (120, 124) to control the amount of overflow polymer material created at the entrance side (112) of an extrusion head (108) during the extrusion of a polymer coating on an elongated metal element (110).

Description

A method to control the amount of polymer material in an extrusion process
Description
Technical Field
[0001 ] The invention relates to a method to control the amount of overflow
polymer material (excess material) created at the entrance side of an extrusion head during the extrusion of a polymer coating on an elongated metal element.
The invention further relates to an equipment to control the amount of overflow polymer material created at the entrance side of an extrusion head.
Background Art
[0002] The application of a polymer coating on an elongated metal element such as a metal wire is well known in the art.
In an extrusion process, the elongated metal element such as the metal wire passes through an extrusion head fed with molten polymer from the extruder. The die (or the last die in case a number of dies is used) in the extrusion head determines the final diameter of the coated product. The final quality of the coated product is for example checked by an automatic diameter control.
[0003] During extrusion material accumulates on the exterior surface of the
entrance of the extrusion head. This overflow polymer material increases gradually until it accumulates to a point where it breaks off, creating waste, possibly causing defects in the product and/or resulting in a shut down of the extrusion line.
Disclosure of Invention
[0004] It is an object of the present invention to provide a method avoiding the drawbacks of the prior art.
It is another object of the present invention to provide a method of applying an extrusion coating allowing extended run times without shutting down the extrusion line.
It is a further object of the present invention to provide a method of applying an extrusion coating with no or limited amount of waste polymer material.
It is still a further object of the present invention to provide a method to avoid specific coating related defects.
It is another object of the present invention to provide an equipment to control the amount of polymer material in an extrusion process. According to a first aspect of the present invention, a method to control the amount of polymer material in an extrusion process is provided. The method comprises the steps of
providing an elongated metal element;
feeding said elongated metal element through an extrusion head of an extruder along axis X, whereby said elongated metal element is entering said extrusion head at the entrance side of said extrusion head and is leaving said extrusion head at the exit side of said extrusion head;
extruding in said extruder a polymer coating on said elongated metal element; said polymer coating being extruded under pressure, thereby creating overflow polymer material at the entrance side of said extrusion head, said overflow polymer material is bulging outward from said entrance side of said extrusion head;
monitoring the thickness of said overflow polymer material at the entrance side of said extrusion head by measuring the thickness of said overflow polymer material along an axis Y, said axis Y being different from axis X, said thickness of said overflow polymer material being defined as the distance between the outer surface of said overflow polymer material and said elongated metal element measured along axis Y;
comparing said thickness of said overflow polymer material with a predetermined minimum value and a predetermined maximum value; in case said thickness of said overflow polymer material is outside the range defined by said predetermined minimum value and said
predetermined maximum value, increasing or decreasing the amount of polymer material to be extruded present in said extruder to restore said thickness of said overflow polymer material in said range defined by said predetermined minimum value and said predetermined maximum value.
[0006] It is an important feature of the method according to the present invention that the polymer coating is extruded in the extruder under pressure. As the polymer material is under pressure in the extruder, the overflow material is bulging outward from the extrusion head at the entrance side of the extrusion head. The overflow polymer material has preferably a convex shape.
[0007] As mentioned above, axis Y is different from axis X. Preferably, the
inclined angle between axis Y and axis X is ranging between 5 and 90 degrees, for example between 30 and 70 degrees, such as 40 degrees, 45 degrees of 50 degrees.
[0008] The amount of polymer material to be extruded that is present in said
extruder can be influenced by
increasing or decreasing the feed of polymer material added to the extruder;
increasing or decreasing the internal pressure in the extruder;
increasing or decreasing the speed of the extrusion screw.
For a person skilled in the art it is clear that the extrusion process can be influenced by a combination of parameters.
[0009] The amount of polymer material in the extrusion process is controlled by monitoring the amount of polymer overflow material. The amount is corrected by increasing or decreasing the amount of polymer material to be extruded in the extruder. Controlling the extrusion process by monitoring the amount of polymer overflow material according to the present invention has several advantages :
In this this way the extruded coating has a constant thickness while no polymer material is wasted. There is no need to provide tools to remove excess material, such as tools to blow of excess material.
As there is no waste material or excess material, for example blown off material, there is no need to provide a recuperation system for waste or excess material.
[0010] The elongated metal element comprises preferably a metal wire or a metal cord, for example a steel wire or a steel cord.
[001 1 ] The elongated metal element may have any type of cross-section.
Preferably, the elongated metal element has a circular cross-section or a flattened cross-section, for example a rectangular or substantially rectangular cross-section.
[0012] In case the elongated metal element has a circular cross-section the
diameter of the elongated metal element ranges preferably between 0.8 and 10 mm, more preferably between 1 and 8 mm, for example 2, 4 or 6 mm.
[0013] In case the elongated metal element has a flattened cross-section, the elongated metal element has preferably a width ranging between 2 and 15 mm, more preferably between 2.4 and 9.2 mm. The thickness ranges preferably between 0.5 and 1 .5 mm, more preferably between 0.8 and 1 .25 mm.
[0014] In preferred embodiments the elongated metal element, such as the steel wire is provided with a zinc or a zinc alloy coating.
[0015] The zinc alloy layer preferably comprises between 2 and 15 % aluminium (Al). Possibly, the zinc alloy coating further comprises between 0.1 and [0016] The zinc or zinc alloy layer can be applied by any conventional technique such as chemical plating, melt plating, melt spraying and electroplating. A preferred method to apply the zinc alloy layer is by hot dip.
[0017] The polymer material may comprise any type of thermoplastic material.
Preferably, the polymer material comprises polyester. Suitable polyester coatings are polyethylene terephthalate (PET), polyethylene naphthalate (PEN) and polybutylene therephthalate (PBT). Within the context of the present application the terms "polyethylene terephthalate" , "polyethylene naphthalate" and "polybutylene therepthalate" denote not only
homopolymers of ethylene terephthalate, ethylene naphthalate and butylene terephthalate but also copolymers of ethylene terephthalate, ethylene naphthalate and butylene terephthalate containing for example not more than 20% of other copolymerized units, e.g. derived from other acids than terephthalic acid, such as isophthalic acid or from other glycols than ethylene glycol. The polymer may also contain mixtures of polymer in order to modify certain of the properties.
[0018] The thickness of the polymer material on the elongated metal element ranges preferably between 15 μιτι and 250 μιτι, more preferably between 30 μιτι and 150 μιτι.
[0019] According to the present invention the amount of overflow polymer
material at the entrance side of said extrusion head is monitored. The monitoring is done by measuring the thickness of the overflow polymer material.
[0020] A preferred method to measure the thickness of the overflow polymer material is by means of an optical device such as a laser beam.
The thickness of the overflow polymer material is preferably measured by projecting a laser beam on the overflow polymer material at the entrance side of the extrusion head. Subsequently, the laser beam is reflected by the overflow polymer material to a laser sensor.
From the reflected laser beam, a thickness of the overflow polymer material is determined. Subsequently, the thus obtained value of the thickness of the overflow polymer material is compared with a
predetermined minimum and maximum value. In case the measured thickness is outside the range determined by the predetermined minimum and maximum value, the amount of polymer material to be extruded present in the extruder is increased or decreased so that the thickness of the overflow polymer material at the entrance side of the extrusion head is in the range determined by the predetermined minimum and maximum value.
[0021 ] According to a second aspect of the present invention, an equipment to control the amount of polymer material in an extrusion process is provided. The equipment comprises
an extruder, said extruder comprising an extrusion head, said extrusion head having an entrance side and an exit side;
a device to monitor the thickness of overflow polymer material
accumulated at said entrance side of said extrusion head;
means to control the extrusion process in such a way that said thickness of said overflow polymer material is inside a range defined by a
predetermined minimum value and a predetermined maximum value.
[0022] The extrusion head defines an axis X. The elongated metal element is introduced in the extrusion head along axis X.
[0023] The thickness of the overflow material is measured along an axis Y. Axis Y is different form axis X.
[0024] In preferred embodiment the device to monitor the thickness of overflow polymer material at the entrance side of an extrusion head comprises a laser.
[0025] The means to control the extrusion process comprise for example - means to increase or decrease the amount of polymer material added to the extruder;
- means to increase or decrease the internal pressure in the extruder;
- means to increase or decrease the speed of the extrusion screw.
Brief Description of Figures in the Drawings
[0026] The invention will now be described into more detail with reference to the accompanying drawings whereby
- Figure 1 is a schematic illustration of an extrusion installation;
- Figure 2 is a schematic illustration of the extrusion head provided with a device to monitor the thickness of overflow polymer material at the entrance side of an extrusion head.
Mode(s) for Carrying Out the Invention
[0027] The present invention will be described with respect to particular
embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.
[0028] Figure 1 shows an equipment 100 comprising an extruder 102. The
extruder 102 comprises a hopper 104, an extrusion screw (not shown) and an extrusion head 108. The hopper 104 feeds material, for example granular material, into the extrusion screw where the material is heated and compressed into a fluent plastic material that is forced through the extrusion head 108 where the fluent plastic material is coated around the wire 1 10 that is being pulled through the extrusion head 108.
Wire 1 10 is entering the extrusion head 108 along axis X at the entrance side 1 12 and coated wire 1 10' is leaving the extrusion head 108 at the exit side 1 14.
As the polymer material is applied under pressure, overflow polymer material or excess polymer material 1 16 is accumulated at the entrance side 1 12 of the extrusion head 108.
The extrusion line can further be provided with a device to take off the wire 1 10, a device to take up the coated wire 1 10', one or more cooling units, one or more heating units, one or more curing units, one or more cleaning units, one or more quality control devices, ... Figure 2 shows a schematic illustration of the cross-section of the extrusion head 108 shown in Figure 1 including the wire 1 10 passing through the extrusion head 108. The die 1 18 determines the final diameter of the coated wire 1 10'.
According to the present invention, the extrusion head 108 is provided with a device 120 to monitor the thickness of the polymer overflow polymer material 1 16 at the entrance side 1 12 of the extrusion head 108. The thickness of the overflow polymer material 1 16 is determined along axis Y. The device 120 comprises for example a laser. A laser beam 122 is projected on the overflow polymer material 1 16 at the entrance side 1 12 of the extrusion head 108. The laser beam 122 is reflected by the polymer overflow polymer material 1 16 to a laser sensor 124. Possibly, the laser sensor 124 is integrated in device 120. From the reflected laser beam 122', a thickness of the overflow polymer material 1 16 is determined.
Subsequently, the thus obtained value of the thickness of the overflow polymer material 1 16 is compared with a predetermined minimum value 126 and a predetermined maximum value 128. In case the measured thickness is outside the range determined by the predetermined minimum value 126 and the predetermined maximum value 128, one or more parameters of the extrusion process are influenced so that the thickness of the polymer overflow polymer material at the entrance side of the extrusion head is in the range determined by the predetermined minimum value 126 and the predetermined maximum value 128.

Claims

Claims
1 . A method to control the amount of polymer material in an extrusion process
- providing an elongated metal element;
- feeding said elongated metal element in an extruder through an extrusion head along axis X, said elongated metal element entering said extrusion head at the entrance side of said extrusion head and leaving said extrusion head at the exit side of said extrusion head;
- extruding in said extruder a polymer coating on said elongated metal
element; said polymer coating being extruded under pressure, thereby creating overflow polymer material at said entrance side of said extrusion head, said overflow polymer material having a convex shape and bulging outward from said entrance of said extrusion head;
- monitoring the amount of said overflow polymer material at the entrance side of said extrusion head by measuring the thickness of said overflow polymer material along an axis Y, said axis Y being different from said axis X, said thickness of said overflow polymer material being defined as the distance between the outer surface of said overflow polymer material and said elongated metal element measured along axis Y;
- comparing said thickness of said overflow polymer material with a
predetermined minimum value and a predetermined maximum value;
- in case said thickness of said overflow polymer material is outside the range defined by said predetermined minimum value and said predetermined maximum value, increasing or decreasing the amount of polymer material to be extruded present in said extruder to restore said thickness of said overflow polymer material in said range defined by said predetermined minimum value and said predetermined maximum value.
2. A method according to claim 1 , wherein said elongated metal element
comprises a metal wire or metal cord.
3. A method according claim 1 or claim 2, wherein said elongated metal element comprises a steel wire.
4. A method according to any one of the preceding claims, wherein said elongated metal element is provided with a zinc or zinc alloy coating.
5. A method according to any one of the preceding claims, wherein said polymer material comprises a thermoplastic material.
6. A method according to any one of the preceding claims, wherein the thickness of said overflow polymer material is measured by a laser.
7. A method according to claim 6, wherein said thickness is measured by
- projecting a laser beam on said overflow polymer material;
- receiving a reflection of said projected laser beam on a laser sensor;
- determining from said reflection of said laser beam a thickness of said
overflow polymer material.
8. An equipment to control the amount of polymer material in an extrusion
process, said equipment comprising
- an extruder, said extruder comprising an extrusion head, said extrusion head having an entrance side and an exit side;
- a device to monitor the thickness of overflow polymer material accumulated at said entrance side of said extrusion head;
- means to control the extrusion process in such a way that said thickness of said overflow polymer material is inside a range defined by a
predetermined minimum value and a predetermined maximum value.
9. An equipment according to claim 8, wherein said device to monitor the
thickness of overflow polymer material accumulated at the entrance side of the said extrusion head comprises a laser.
PCT/EP2014/069204 2013-09-19 2014-09-09 A method to control the amount of polymer material in an extrusion process WO2015039929A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP13185140.4 2013-09-19
EP13185140 2013-09-19

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114801120A (en) * 2022-05-06 2022-07-29 杨娉 A shaping extrusion device for wire and cable processing

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JP2004268369A (en) * 2003-03-07 2004-09-30 High Frequency Heattreat Co Ltd Method and apparatus for manufacturing resin coated wire material
JP2004291312A (en) * 2003-03-26 2004-10-21 Nippon Zeon Co Ltd Method and apparatus for manufacturing coated metal wire material
US20060260739A1 (en) * 2005-05-16 2006-11-23 Joseph Varkey Methods of manufacturing composite slickline cables

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Publication number Priority date Publication date Assignee Title
US2770014A (en) * 1953-08-25 1956-11-13 Itt Sizing of thermoplastic cable cores
JPS50152290A (en) * 1974-05-29 1975-12-08
JP2001247340A (en) * 2000-03-01 2001-09-11 Furukawa Electric Co Ltd:The Method for coating optical fiber and coating apparatus
JP2004268369A (en) * 2003-03-07 2004-09-30 High Frequency Heattreat Co Ltd Method and apparatus for manufacturing resin coated wire material
JP2004291312A (en) * 2003-03-26 2004-10-21 Nippon Zeon Co Ltd Method and apparatus for manufacturing coated metal wire material
US20060260739A1 (en) * 2005-05-16 2006-11-23 Joseph Varkey Methods of manufacturing composite slickline cables

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114801120A (en) * 2022-05-06 2022-07-29 杨娉 A shaping extrusion device for wire and cable processing
CN114801120B (en) * 2022-05-06 2023-12-22 河南九发电工科技有限公司 A shaping extrusion device for wire and cable processing

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