Lamella Block with Lamella Openings

Abstract

A lamella block for a calibration device for the calibration of an extruded profile, wherein the lamella block includes a lamella structure having a plurality of lamellae, which are spaced apart from one another by grooves and arranged in the longitudinal direction of the lamella block. At least some of the lamellae are provided with at least one lamella opening with a predefined variable geometry. The application also relates to a method for producing said lamella. block, as well as a calibration device comprising a plurality of said lamella blocks. The application further relates to a system for additively manufacturing said lamella block, a corresponding computer program and corresponding data set.

Claims

1-19. (canceled)

20. A lamella block (100) for a calibrating device (500) for calibrating an extruded profile (550), wherein the lamella block (100) comprises a lamella structure (110), 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), characterized in that at least several of the lamellae (112) are provided with at least one lamella opening (115) with a prescribed, variable geometry, wherein the geometry of lamella openings (115) varies within a lamella (112).

21. The lamella block (110) according to claim 20, wherein the geometry of the lamella openings (115) of sequential lamellae (112) varies.

22. The lamella block (100) according to claim 20, wherein the lamella openings (115) of sequential lamellae (112) are arranged offset relative to each other.

23. The lamella block (110) according to claim 20, wherein the lamella block (100) further has a carrier structure (120) on which the lamellae (112) of the lamella structure (110) are fastened.

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

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

26. A calibrating device (500) for calibrating extruded profiles (510), comprising a plurality of lamella blocks (100) according to claim 20, wherein the lamella blocks (100) are arranged relative to each other to form a calibrating opening (510).

27. The calibrating device according to claim 26, 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), so as to individually activate each lamella block (100).

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

29. The method according to claim 28, further comprising 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.

30. The method according to claim 29, wherein the step of calculating the 3D lamella block geometry comprises: Calculating lamella openings (115), wherein the number of lamella openings (115) and/or the geometry of the lamella openings (115) is calculated individually for each lamella (112).

31. A method for manufacturing a lamella block (100), which comprising the following steps: generating a dataset, which images the lamella block (100) 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) imaged in the dataset.

32. 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) with the features according to claim 20.

33. A computer-readable data carrier, which stores the computer program according to claim 32.

Description

[0033] Additional advantages, details and aspects of the present invention are discussed based on the drawings below. Shown on:

[0034] FIG. 1 is a lamella block for a calibrating device according to prior art;

[0035] FIG. 2 is another lamella block for a calibrating device according to prior art;

[0036] FIGS. 3a/3b are views of another lamella block according to prior art;

[0037] FIG. 4a/4b are views of a lamella block according to the invention;

[0038] FIG. 5 is a block diagram of a method for manufacturing the lamella block according to the invention on FIGS. 4a and 4b; and

[0039] FIG. 6 is a calibrating device according to the present invention.

[0040] FIGS. 1, 2, 3a and 3b were already discussed at the outset in conjunction with prior art. Let reference be made to the description there.

[0041] In conjunction with FIGS. 4a and 4b, an example for a lamella block 100 according to the invention for a calibrating device will now be described further. FIG. 4a shows a three-dimensional view of the lamella block 100. FIG. 4b shows a front view of the lamella block 100 corresponding thereto.

[0042] The lamella block 100 comprises a carrier structure 120 as well as a lamella structure 110, which comprises a plurality of lamellae 112. The carrier structure 120 acts as a carrier for the lamella structure 110.

[0043] The lamella block 100 can further have a coupling device (not shown on FIGS. 4a and 4b). The coupling device is provided for coupling with an activating device of a calibrating device. The activating device is likewise not visible on FIGS. 4a and 4b. According to one implementation, the coupling device can have two or more threaded holes spaced apart from each other. The threaded holes can be integrated into the carrier structure 120.

[0044] The carrier structure 120 is designed as a massive body. The carrier structure 120 has a rectangular profile in the cross section perpendicular to the longitudinal direction. Other profiles deviating from a rectangular cross sectional profile are likewise conceivable. Instead of the massive carrier body shown on FIG. 4a, the lamella block 100 can also have several carrier rods, to which the lamellae 112 are fastened.

[0045] The lamella structure 110 of the lamella block 100 according to the invention will now be described in more detail. The lamella structure 110 comprises a plurality of lamellae 112, which are spaced apart from each other in the longitudinal direction L of the lamella block 100 (see FIG. 4a). Neighboring lamellae 112 are separated from each other by corresponding grooves 114. Each lamella 112 has a triangular cross sectional profile relative to the longitudinal direction L. Each lamella 112 further has a lamella surface 113 that faces away from the carrier structure 120, and is slightly curved in design. The lamella surface 113 faces the profile to be calibrated. It forms the contact surface with the profile to be calibrated. Depending on the application, the lamella block 100 can also have a different lamella shape that can deviate from the triangular cross sectional profile described here. The lamella surface 113 facing the profile to be calibrated can likewise be flat or have some other kind of curvature.

[0046] As further denoted on FIGS. 4a and 4b, at least several of the lamellae 110 arranged along the lamella block 100 have openings 115. The lamella 112 on the front side of the lamella block 100 shown on FIGS. 4a and 4b exemplarily has six lamella openings 115, which each penetrate the lamella 112 in a longitudinal direction L of the lamella block 100 (essentially along a straight line). The essential difference between the individual lamella openings 115 lies in their geometric configuration. As readily discernible from the front side view on FIG. 4b, the six openings 115 differ from each other in terms of their cross sectional shape and cross sectional expansion. The cross sectional shape and cross sectional expansion of the openings 115 here varies as a function of their arrangement within the lamella 112. For example, the openings arranged in the lamella center have a significantly larger cross sectional expansion than those openings 115 arranged at the tapered outer areas of the lamella 112. Much the same otherwise also holds true for the cross sectional shape of the individual lamella openings 115, which are correspondingly adjusted to the triangular cross sectional shape of the lamella 112. Individually adjusting the (cross sectional) geometry of the openings 115 to the lamella geometry as described here makes it possible to optimize (maximize) the overall opening surface generated by the lamella openings 115, without significantly weakening the mechanical stability of the lamella 112. Optimizing (maximizing) the opening surface makes it possible to distinctly improve (optimize) the cooling function of the lamella 112.

[0047] The openings 115 shown on FIGS. 4a and 4b are purely exemplary. It goes without saying that the number of openings 115 per lamella 112 is not limited to six openings 115, but instead can vary depending on the cooling requirement of a lamella 112. Likewise, the cross sectional geometry (in particular the cross sectional shape) of the openings 115 is not limited to the one on FIGS. 4a and 4b. The openings 115 can have cross sectional shapes that are elliptical, semicircular, circular, triangular, rectangular and/or otherwise polygonal. It is critical that the number and/or cross sectional geometry of the openings be correspondingly adjusted to the cooling requirement of the respective lamella.

[0048] As further evident from FIGS. 4a and 4b, the carrier structure 120 is integrally designed together with the lamella structure 110. A generative or additive manufacturing process can preferably be used to manufacture the lamella block 100 with variable lamella openings 115 shown on FIGS. 4a and 4b. This type of manufacturing process is shown on FIG. 5, and will be described in more detail below.

[0049] Use is thus made of a 3D printing process. In a first step S10, a 3D lamella block geometry (CAD data) is here calculated. In particular, the 3D lamella block geometry (or the CAD data describing the 3D lamella block geometry) comprise the individually adjusted lamella openings provided for each lamella. The number, geometry and arrangement of lamella openings can here be individually calculated for each lamella taking prescribed model parameters into account (for example, the geometry of the lamella, material of the lamella, thermal and mechanical properties of the lamella).

[0050] In a subsequent second step S20, the calculated 3D geometry data are converted into control commands for operating a 3D printer. The 3D printer can be configured for executing a 3D printing process (e.g., a laser sintering process or laser melting process).

[0051] Based on the generated control commands, the lamella block 100 is then built up layer by layer with the 3D printer (step S30). A metal material or a polymer material can be used as the material for 3D printing.

[0052] The 3D printing process described here for manufacturing the lamella blocks according to the invention is advantageous, since any opening shapes required can be realized in the lamellae. The opening shapes need not remain confined to uniform, circular holes, but can instead be variably designed depending on the cooling requirement (and lamella geometry). The arrangement and geometry of the openings can be optimized for each lamella, with the objective of exposing the lamella to an optimal cooling, for example while it is being submerged in the cooling water sump of the calibrating basket.

[0053] 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.

[0054] The calibrating device 500 comprises a plurality of the lamella blocks 100 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 further schematically denoted on FIG. 5, the neighboring lamella blocks 100 can be intermeshing in design. To this end, the lamellae 112 and grooves 114 of neighboring lamella blocks 100 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 can mesh into each other in a comb-like manner.

[0055] 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. The activating devices 520 are provided to displace the respective lamella blocks 100 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.

[0056] The calibrating device 500 further comprises a housing 530 for receiving the activating devices 520 and the lamella blocks 100. 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.