Fin block for a calibrating device

Abstract

A fin block is provided for a calibrating device for the calibrating of an extruded plastic profile, wherein the fin block includes a back structure and a fin structure having a plurality of fins. The fins are spaced apart from one another and arranged on the back structure in longitudinal direction (L) of the back structure. The back structure of the fin block has a plurality of apertures, the shape and/or arrangement of which within the back structure depends on a predetermined mechanical load capacity for the back structure. Furthermore, a method for the production of the above-mentioned fin block and a calibrating device, which includes a plurality of the above-mentioned fin blocks, is provided. Furthermore, a system for the additive manufacture of the above-mentioned fin block, a corresponding computer program and a corresponding data set is provided.

Claims

1. A fin block for a calibrating device for calibrating an extruded profile, the fin block comprising: a back structure extending between opposite first and second ends thereof in a longitudinal direction of the fin block; and a fin structure having a plurality of fins, wherein the plurality of fins are spaced apart from one another and arranged on the back structure in the longitudinal direction of the back structure, wherein the plurality of fins extend directly outwards from the back structure, wherein the back structure has opposite first and second end portions and a middle portion disposed therebetween, the first end portion being disposed adjacent the first end of the back structure and the second end portion being disposed adjacent the second end of the back structure, wherein each of the first and second end portions and the middle portion of the back structure has a plurality of apertures extending therethrough in a direction perpendicular to the longitudinal direction of the back structure, the shape and/or arrangement of which within the back structure depends on a predetermined mechanical load capacity for the back structure, wherein a cross-sectional shape and size of one aperture of the plurality of apertures extending through the first end portion are different than a cross-sectional shape and size of one aperture of the plurality of apertures extending through the middle end portion, wherein the apertures are configured in their cross-sectional shape and arranged along the back structure in such a way that the back structure has an optimized dead weight whilst maintaining the predetermined mechanical load capacity.

2. The fin block according to claim 1, wherein the back structure has a profile which is predetermined in cross-section to the longitudinal direction and is adapted to the predetermined mechanical load capacity.

3. The fin block according to claim 1, wherein the fin block is formed in one piece.

4. The fin block according to claim 1, wherein the back structure and the fin structure are made from the same material or from different materials.

5. The fin block according to claim 1, wherein the back structure and/or the fin structure are formed from a metallic material or from a polymer material.

6. The fin block according to claim 1, wherein the fin block is produced by means of 3D printing or respectively by means of an additive manufacturing method.

7. The fin block according to claim 1, wherein the back structure has first and second bores formed therein and spaced from one another in the longitudinal direction, wherein each of the first and second bores extends perpendicularly to the longitudinal direction and in a direction from a top wall of the back structure towards the fin structure, and wherein the middle portion of the back structure extends between said first and second bores.

8. The fin block according to claim 1, wherein a cross-sectional shape and size of one aperture of the plurality of apertures extending through the second end portion are the same as the cross-sectional shape and size of said one aperture extending through the first end portion.

9. The fin block according to claim 1, wherein the plurality of apertures extending through the first end portion of the back structure are defined by a frame defining a single cut-out in the first end portion, and a pair of intersecting struts that subdivide said single cut-out into said plurality of apertures.

10. The fin block according to claim 1, wherein the back structure has first and second bores formed therein and spaced from one another in the longitudinal direction, wherein each of the first and second bores extends perpendicularly to the longitudinal direction and in a direction from a top wall of the back structure towards the fin structure, and wherein the middle portion of the back structure extends between said first and second bores, wherein a cross-sectional shape and size of one aperture of the plurality of apertures extending through the second end portion are the same as the cross-sectional shape and size of said one aperture extending through the first end portion, and wherein the plurality of apertures extending through the first end portion of the back structure are defined by a frame defining a single cut-out in the first end portion, and a pair of intersecting struts that subdivide said single cut-out into said plurality of apertures.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages, details and aspects of the present invention are discussed further with the aid of the following drawings. There are shown:

(2) FIG. 1 a fin block for a calibrating device according to the prior art;

(3) FIG. 2 a further fin block for a calibrating device according to the prior art;

(4) FIG. 3 a sectional view of a further fin block according to the prior art;

(5) FIG. 4 an example of a fin block according to the invention; and

(6) FIG. 5 a block diagram of a method for the production of the fin block according to the invention.

DESCRIPTION OF EXAMPLE EMBODIMENTS

(7) FIGS. 1 to 3 were already discussed in the introduction in connection with the prior art. Reference is to be made to the description there.

(8) In connection with FIG. 4, an example of a fin block 100 according to the invention for a calibrating device is now described further.

(9) The fin block 100 comprises a back structure 120 and a fin structure 110, which has a plurality of fins 112. The back structure 120 functions as a carrier for the fin structure 110.

(10) The fin block 100 can have, furthermore, a coupling device 130 which is provided for coupling with an actuating device of a calibrating device. The actuating device can not be seen in FIG. 4. According to the implementation shown in FIG. 4, the coupling device comprises two threaded bores 130, arranged spaced apart from one another. The threaded bores 130 can be formed in an integrated manner in the back structure 120.

(11) The fin structure 110 comprises a plurality of fins 112, which are arranged spaced apart from one another in longitudinal direction L of the fin block 100. Adjacent fins 112 are separated from one another by corresponding grooves 114. In the embodiment illustrated in FIG. 4, each fin 112 has a profile which is triangular in cross-section to the longitudinal direction L. The fin side 113 facing away from the back structure 120 is configured so as to be slightly curved. The fin side 113 faces the profile which is to be calibrated. It forms the contact side with the profile which is to be calibrated. Depending on the application, the fin block 100 can also have a different fin shape which can differ from the triangular cross-section profile described here. Likewise, the fin side 113 facing the profile which is to be calibrated can be flat or can have a different curvature.

(12) The back structure 120 is formed as an elongated body with a predetermined cross-section profile 121 perpendicularly to the longitudinal direction L. In the embodiment shown in FIG. 4, the back structure 120 has a T profile. Other profiles, such as for example an I profile are likewise conceivable. The cross-section profile 121 of the back structure 120 can be selected accordingly depending on the load forces which are to be expected acting on the back structure 120.

(13) Irrespective of the practical cross-section profile (T profile or I profile), a plurality of apertures 122, 122a (perforations) are formed in the back structure 120 in longitudinal direction L. These apertures 122, 122a run substantially perpendicularly to the longitudinal direction L. They connect the two lateral flanks 128, 129 of the back structure 120. A back structure 120 with a predetermined cross-section profile 121 is thus produced, which is penetrated at its lateral flanks 128, 129.

(14) As can be seen further from FIG. 4, the design (more precisely the shape and/or the size) of the individual apertures 122, 122a varies in longitudinal direction L of the back structure 120. The two end portions 123 of the back structure 120 have, partially, apertures 122 with smaller cross-section openings than the middle portion 125 (cf. in particular the two centrally arranged apertures 122a), because this portion is exposed to fewer mechanical stresses during operation of the calibrating machine than the two opposite end portions 123 in longitudinal direction L. In addition to the size, the shape of the apertures 122, 122a (the shape of the cross-section openings of the apertures 122, 12a) can also be varied accordingly depending on the mechanical stresses acting on a portion of the back structure 120. For example, the end portions 123 of the back structure 120 are provided with triangular apertures 122, whereas the middle portion 125 has apertures 122a which differ from the triangular shape.

(15) Generally it can be stated that according to the present invention the size and/or shape of the apertures 122, 122a are formed depending on the mechanical load forces acting on the back structure 120. In particular, the size and/or shape of the apertures 122a formed in the back structure 120 can vary along its longitudinal direction L, because during operation the fin block 100 can be exposed to different forces in longitudinal direction L.

(16) In the embodiment illustrated in FIG. 4, the apertures 122, 122a are furthermore dimensioned and arranged in such a way that the back structure 120, in addition to a predetermined mechanical load capacity also has a reduced (minimized) dead weight. The result of such a weight optimization whilst maintaining the predetermined mechanical load capacity is a back structure 120, which owing to the apertures 122, 122a is configured substantially in a frame-shaped manner and has struts 124, 124a in the interior of the frame. The shape of the struts 124, 124a depends on the local load capacity requirements for the back structure 120 and can vary in longitudinal direction L of the back structure 120.

(17) The (maximum) reduction, described here, of the dead weight of the back structure 120 whilst maintaining predetermined load capacity requirements can be simulated by means of a mathematical model for each fin block 100 (cf. by means of finite elements simulation). According to the simulation results and the topology of the apertures 122, 122a resulting therefrom, the back structure 120 can be produced accordingly.

(18) For the production of the back structure 120 (or respectively of the entire fin block 120) a generative or respectively additive manufacturing method can be used. Such a production method is shown in FIG. 5. Accordingly, a 3D printing method is used. Here, in a first step on the basis of the simulation described above, which simulates a suitable topology of the back structure 120, 3D geometry data (CAD data) are calculated. The 3D geometry data describe the geometry of the back structure (or respectively of the entire fin block 100). In a second step, the calculated 3D geometry data are converted into control commands for a 3D printing. Based on the generated control commands, the back structure (or the entire fin block 100) is then built up layer by layer by means of a 3D printing method (e.g. laser sintering, laser melting). A metallic material or a polymer material can be used as material for the 3D printing.

(19) Alternatively to the production by means of 3D printing, it is also conceivable to produce the back structure 120 (or respectively the entire fin block 100) from a workpiece (for example by milling, drilling, cutting) or by means of a casting method.

(20) The fin block 100 shown in FIG. 4 can form, together with a plurality of further similar fin blocks 100, a calibration basket for a calibrating device. The arrangement of the plurality of fin blocks 100 for the formation of a calibration basket with predetermined calibration cross-section can take place in an analogous manner to as described in DE 198 43 340 A1.

(21) It shall be understood that the fin block 100 shown in FIG. 4 is by way of example and other geometries are conceivable in the configuration of the fins 122 and also in the configuration of the back structure 110. It is essential for the present invention that the back structure 120 has apertures 122, 122a, the shape and/or arrangement of which is adapted to the anticipated occurring mechanical stresses and can vary within the back structure. The apertures 122, 122a are therefore not restricted only to uniform circular bores, in order to enable a penetration of water. Rather, the individual apertures 122, 122a are optimized in their shape and structure to the effect that the back structure 120 has substantially less material and, at the same time, has as high a mechanical load capacity as possible. Therefore, not only can the material usage be further reduced, but also the overall weight of calibrating devices into which the fin block, described above, can be installed. Furthermore, the splashing behaviour and the cooling are further improved through the design of the back structure which is described here. Furthermore, the production costs of the fin block decrease through the reduced material usage.