Lamella Block with Continuously Varied Lamella Division

Abstract

A lamella block is provided for a calibrating device for calibrating an extruded profile, wherein the lamella block includes a lamella structure, which has a plurality of lamellae that are spaced apart from each other by grooves and arranged in the longitudinal direction of the lamella block. The lamella structure has a variably designed division in the longitudinal direction of the lamella block. Further provided is a method for manufacturing the aforementioned lamella block, as well as a calibrating device, which includes a plurality of the lamella blocks mentioned above. Also provided is a system for additively fabricating the lamella blocks mentioned above, a corresponding computer program and a corresponding dataset.

Claims

1.-19. (canceled)

20. A lamella block (100, 100a) for a calibrating device (500) for calibrating an extruded profile (550), wherein the lamella block (100, 100a) comprises a lamella structure (110, 110a), which has a plurality of lamellae (112) that are spaced apart from each other by grooves (114) and arranged in the longitudinal direction of the lamella block (100, 100a), characterized in that the lamella structure (110, 110a) has a variably designed division in the longitudinal direction of the lamella block (100, 100a), wherein the division of the lamella structure (110, 110a) in the longitudinal direction of the lamella block (100, 100a) varies according to a prescribed function.

21. The lamella block (100, 100a) according to claim 20, wherein the division of the lamella structure (110, 11a) in the longitudinal direction of the lamella block (100, 100a) varies continuously.

22. The lamella block (100, 100a) according to claim 20, wherein the division of the lamella structure (110, 11a) in the longitudinal direction of the lamella block (100, 100a) varies randomly.

23. The lamella block (100, 100a) according to claim 20, wherein the lamella structure (110, 110a) has grooves (114) with a variable groove width in the longitudinal direction of the lamella block (100, 100a).

24. The lamella block (100, 100a) according to claim 20, wherein the lamella structure (110, 110a) has lamellae (112) with a variable lamella width in the longitudinal direction of the lamella block (100, 100a).

25. The lamella block (100, 100a) according to claim 20, wherein the lamella block (100, 100a) further has a carrier structure (120), on which the lamella structure (110, 110a) is arranged.

26. The lamella block (100, 100a) according to claim 25, wherein the carrier structure (120) and the lamellae (112) are fabricated out of the same material or different materials.

27. The lamella block (100, 100a) according to claim 20, wherein the lamella block (100, 100a) is integrally designed.

28. The lamella block (100, 100a) according to claim 20, wherein the lamella block (100, 100a) is manufactured by means of 3D printing or an additive manufacturing process.

29. A calibrating device (500) for calibrating extruded profiles (550), comprising a plurality of lamella blocks (100, 100a) according to claim 20, wherein the lamella blocks (100, 100a) are arranged relative to each other to form a calibrating opening.

30. The calibrating device according to claim 29, wherein the calibrating device (500) comprises a plurality of activating devices (520), wherein each activating device (520) is coupled with a respective lamella block (100, 100a), so as to individually activate each lamella block (100, 100a).

31. A method for manufacturing a lamella block (100, 100a) according to claim 20, involving the step of manufacturing the lamella block (100, 100a) by means of 3D printing or additive manufacturing.

32. The method according to claim 31, further involving the step of calculating a 3D lamella block geometry, and converting the calculated 3D geometry data into corresponding control commands for 3D printing or additive manufacturing.

33. A method for manufacturing a lamella block (100, 100a), which involves the following steps: generating a dataset, which images the lamella block (100, 100a) according to claim 20; storing the dataset on a storage device or a server; and inputting the dataset into a processing device or a computer, which actuates an additive manufacturing device in such a way that the latter fabricates the lamella block (100, 100a) imaged in the dataset.

34. A computer program, comprising datasets, which while the datasets are being read in by a processing device or a computer, prompts the latter to actuate an additive manufacturing device in such a way that the additive manufacturing device fabricates a lamella block (100, 100a) with the features according to claim 20.

35. A computer-readable data carrier, which stores the computer program according to claim 34.

Description

[0029] Additional advantages, details and aspects of the present invention are discussed based on the drawings below. Shown on:

[0030] FIG. 1 is a 3D view of a lamella block for a calibrating device according to prior art;

[0031] FIG. 2a/2b are views of another lamella block for a calibrating device according to prior art;

[0032] FIG. 3 is a view of a lamella block according to the present invention;

[0033] FIG. 4 is a view of another lamella block according to the present invention;

[0034] FIG. 5 is a block diagram of a method for manufacturing the lamella block describe don FIGS. 3 and 4; and

[0035] FIG. 6 is a calibrating device according to the present invention.

[0036] FIGS. 1, 2a and 2b were already discussed at the outset in conjunction with prior art. Let reference be made to the description there.

[0037] In conjunction with FIG. 3, a lamella block 100 according to the invention will now be described further. FIG. 3 shows a view of an interior side of the lamella block 100. Interior side denotes that side of the lamella block 100 that faces a profile to be calibrated.

[0038] The lamella bock 100 comprises a lamella structure 110, which comprises a plurality of lamellae 112 and grooves 114, which separate neighboring lamellae 112 from each other. As a consequence, the free spaces (distances) between sequential lamellae 112 are labeled as grooves 114. In the view shown on FIG. 3, each individual lamella 112 of the lamella structure 110 is shown in the form of a transverse beam. The lamella block 100 further comprises a carrier structure 120 for receiving (storing) the lamellae 112 (or lamella structure 110). The carrier structure 120 along which the lamellae 112 are arranged is denoted as a longitudinal beam (horizontal beam) on FIG. 3.

[0039] The carrier structure 120 can have a back structure with a block-shaped design. The back structure can be realized by a beam-shaped body, along which the lamellae 112 are arranged. In particular, the beam-shaped back structure can have holes for reducing the weight. As a consequence, the carrier structure 120 can be designed exactly like the carrier structure of the lamella block 20 described in conjunction with FIGS. 2a and 2b. Let reference be made to the corresponding description for FIGS. 2a and 2b. Alternatively, the carrier structure 120 can have at least one carrier rod, on which the lamellae 112 are threaded, just as described at the outset in conjunction with the lamella block on FIG. 1. The distance (grooves) between sequential lamellae 112 is realized in the threaded lamella block by means of spacer sleeves of a suitable length.

[0040] The lamellae 112 of the lamella structure 110 each have a prescribed cross sectional profile perpendicular to the longitudinal direction L of the lamella block 100. The cross sectional profile of each lamella 112 can here correspond to the cross sectional profile of the lamellae shown on FIG. 1 or 2a. Each lamella 112 further has a lamella surface 113 that faces the profile to be calibrated. The lamella surfaces 113 of the lamellae 112 form a contact surface, with which the profile to be calibrated comes into contact. The lamella surface 113 facing the profile to be calibrated can also be flat in design, or have a curved surface.

[0041] As further evident from FIG. 3, all lamellae 112 of the lamella structure 110 have the same width d in the longitudinal direction L of the lamella block 100. However, the distances (i.e., the groove width areas) between sequential lamellae 112 differ in the longitudinal direction L. The lamella structure 110 on FIG. 3 has a sequence of n grooves 114 in the longitudinal direction L, wherein the width D.sub.1, D.sub.2, . . . D.sub.n (n is a natural number) of the individual grooves 114 varies. Continuously varying the groove widths D.sub.1, D.sub.2, . . . D.sub.n thus yields a lamella structure 110 with a variable division in the longitudinal direction L. As a consequence, the lamella structure 110 has a sequence of n sequential divisions T.sub.1, T.sub.2, . . . T.sub.n (n is a natural number) with a variable division length in the longitudinal direction L. Division (or division length) here refers to the length of the base unit that builds up on the lamella structure 110, which consists of a lamella 112 and its adjoining groove 114. In other words, each division T.sub.i (with i=1, n, wherein n is a natural number) along the lamella structure 110 corresponds to the sum of the width d of the corresponding lamella 112 and the width D of the groove 114 that adjoins the lamella 112.

[0042] In the lamella structure 110 shown on FIG. 3, the variation (change) in groove widths D.sub.1, D.sub.2, . . . D.sub.n (and hence the variation of divisions T.sub.1, T.sub.2, . . . T.sub.n) in the longitudinal direction L (i.e., along the lamella block 100) takes place continuously. Continuous variation means that neighboring divisions within the division sequence T.sub.1, T.sub.2, . . . T.sub.n have varying division lengths. The lamella structure 110 thus has no lamella structure areas within which the division remains constant.

[0043] The variation of divisions T.sub.1, T.sub.2, . . . T.sub.n along the lamella structure 110 is further selected randomly. The variation of divisions T.sub.1, T.sub.2, . . . T.sub.n in a longitudinal direction L follows no prescribed pattern (functional correlation). In particular, the division sequence T.sub.1, T.sub.2, . . . T.sub.n within the lamella structure 110 has no periodicity. Instead, divisions with larger and smaller division lengths alternate, wherein the division lengths are random.

[0044] Another lamella block 100a according to the present invention is described in conjunction with FIG. 4. The lamella block 100a once again has a lamella structure 110a with a plurality of lamellae 112 arranged spaced apart from each other. The lamella block 100a further has a lamella carrier 120 that carries the lamella structure 110a. The lamella carrier 120 and lamellae 112 can be designed exactly as in the lamella block 100 on FIG. 3. In particular, the lamellae 112 of the lamella structure 110 once again have a prescribed, uniform width d. For simplification purposes, the lamella carrier 110 and the lamellae 122 are provided with the same reference numbers as in the lamella block 100 on FIG. 3. Reference is further made to the corresponding description of the lamellae 112 and the lamella carrier 110 in conjunction with the FIG. 3 further above.

[0045] The difference between the lamella block 100 on FIG. 3 and the lamella block 100a on FIG. 4 lies in the formation of the lamella structure 110a. As in the lamella structure 100 on FIG. 3, the lamellae 112 of the lamella structure 110a each have the same width d. In addition, the width D.sub.i (with i=1, n, wherein n is a natural number) of the grooves 114 in a longitudinal direction L of the lamella block 100a varies continuously. As a consequence, the divisions T.sub.i (with i=1, n, wherein n is a natural number) also vary in the longitudinal direction L. However, the continuous variation of divisions in the longitudinal direction L is not random (as in the lamella structure 110 on FIG. 3), but follows a constant function. Based on the implementation shown on FIG. 4, the division of the lamella structure 110a in the longitudinal direction L varies according to a linear function. Proceeding from a first end of the lamella structure (left end on FIG. 4), the division length of the divisions T.sub.1, T.sub.2, . . . T.sub.n linearly decreases continuously up to a second end of the lamella structure 110a (right end on FIG. 4). It goes without saying that the linear decrease in division lengths described here is only exemplary, and that another functional variation of the divisions is just as conceivable. It is only critical that the variation of the division within the lamella structure be such that no lamella areas with a constant division arise.

[0046] Continuously varying the division along the lamella structure 110 as described in conjunction with FIGS. 3 and 4 prevents the bulges (caused by the lamella structure itself) that arise during calibration on the surface of the profile to be calibrated from dropping into subsequent grooves of the lamella blocks time and again while advancing the profile to be calibrated through the calibrating basket. The varying position and size of the grooves (and hence of the bulges on the surface of the profile to be calibrated) effectively prevents bulges from being able to fall into sequential grooves.

[0047] A generative or additive manufacturing process can be used to manufacture the lamella blocks 100, 100a illustrated on FIGS. 3 and 4. This type of manufacturing process is shown on FIG. 5. In a first step S10, 3D geometry data (CAD data) are here calculated for the lamella block 100, 100a. The 3D geometry data describe the geometry of the entire lamella block 100, 100a comprising the carrier structure 110 and the lamella structure 110, 110a. In a subsequent second step S20, the calculated 3D geometry data are converted into control commands for 3D printing. Based on the generated control commands, the lamella block 100 (in its entirety) is then built up layer by layer by means of a 3D printing process (e.g., laser sintering, laser melting) (step S30). A metal material or a polymer material can be used as the material for 3D printing.

[0048] As an alternative to manufacturing via 3D printing as described here, it is also conceivable that the lamella blocks 100, 100a be fabricated out of a workpiece (for example by milling, drilling, cutting) or in a casting process.

[0049] Described in conjunction with FIG. 6 is a calibrating device 500 for calibrating an extruded plastic profile 550. FIG. 6 shows a sectional view of the calibrating device 500. The profile 550 to be calibrated is a pipe profile in the implementation depicted on FIG. 6.

[0050] The calibrating device 500 comprises a plurality of the lamella blocks 100, 100a according to the invention described above, which are arranged in such a way relative to each other in the peripheral direction of the calibrating device 500 as to form a calibration basket 505 with a desired calibrating opening 510. As denoted on FIG. 6, the neighboring lamella blocks 100, 100a can be intermeshing in design. To this end, the lamellae 112 and grooves 114 of neighboring lamella blocks 100, 100a are tailored to each other in terms of their arrangement and dimensions (in particular in terms of the groove width and lamella width) in such a way that the lamellae 112 of neighboring lamella blocks 100, 100a can mesh into each other in a comb-like manner.

[0051] The calibrating device 500 further comprises a plurality of activating devices 520 (for example, linear actuators), wherein one respective activating device 520 is coupled with one lamella block 100, 100a. The activating devices 520 are provided to displace the respective lamella blocks 100, 100a in a radial direction (i.e., perpendicular to the feed direction of the profile to be calibrated). This makes it possible to correspondingly adjust the active cross section of the calibrating opening to the profile to be calibrated.

[0052] The calibrating device 500 further comprises a housing 530 for receiving the activating devices 520 and the lamella blocks 100, 100a. The housing 530 can be cylindrical in design. It can have an inner housing cylinder 530a and an outer housing cylinder 530b, wherein components of the activating device 520 can be arranged in the gap between the inner housing cylinder 530a and the outer housing cylinder 530b, similarly to the calibrating device described in DE 198 43 340 C2.

[0053] The lamella blocks with a continuously varied division described here prevent a periodic bulge pattern from forming on the profile surface of the profile to be extrude. Since the bulge pattern is irregular in design, generated bulges are prevented from falling into subsequent grooves of the lamella blocks while feeding the extruded profile. This prevents the rattling described at the outset during a calibrating process. In addition, the surface structure of the extruded profile is improved, since the changing division of the lamella structure prevents the lamella structure from being repeatedly embossed on the same positions on the profile surface.