U.S. patent application number 10/454491 was filed with the patent office on 2003-11-06 for extrusion molding apparatus for product having wood pattern and extrusion molding method thereof.
Invention is credited to Lee, Moon Jae.
Application Number | 20030207084 10/454491 |
Document ID | / |
Family ID | 26639364 |
Filed Date | 2003-11-06 |
United States Patent
Application |
20030207084 |
Kind Code |
A1 |
Lee, Moon Jae |
November 6, 2003 |
Extrusion molding apparatus for product having wood pattern and
extrusion molding method thereof
Abstract
An extrusion molding apparatus for a product having a wood
pattern and an extrusion molding method are disclosed, in which a
second synthetic resin containing a wood powder of 80.about.120
meshes at a predetermined ratio is fed to a die through a second
extruder and then is coated on a surface of the product, thereby
providing an esthetic surface and an improved durability. The
extrusion molding apparatus is designed to successively produce a
product having a wood pattern with a predetermined sectional shape
by feeding a thermoplastic synthetic resin to an extruder and
extruding the product through a die installed at an outlet of the
extruder, wherein a second inlet is formed at one side of the die
to fit a second synthetic resin thereinto, a second extruder which
feeds the second synthetic resin is connected to the second inlet,
and a second passage communicated with the second inlet of the die
is formed to communicate with an original synthetic resin passage
formed in the die, thereby coating the second synthetic resin on a
surface of the product extruded from the die.
Inventors: |
Lee, Moon Jae; (Bucheon-Si,
KR) |
Correspondence
Address: |
McGuireWoods LLP
Suite 1800
1750 Tysons Boulevard
McLean
VA
22102
US
|
Family ID: |
26639364 |
Appl. No.: |
10/454491 |
Filed: |
June 5, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10454491 |
Jun 5, 2003 |
|
|
|
10058057 |
Jan 29, 2002 |
|
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Current U.S.
Class: |
428/151 ;
428/17 |
Current CPC
Class: |
B29C 48/12 20190201;
B29C 48/175 20190201; B29C 48/49 20190201; B29C 48/21 20190201;
Y10T 428/24438 20150115; B29C 48/11 20190201; B29C 48/09 20190201;
B29C 48/34 20190201 |
Class at
Publication: |
428/151 ;
428/17 |
International
Class: |
A41G 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 26, 2001 |
KR |
2001-59553 |
Sep 26, 2001 |
KR |
2001-59554 |
Claims
What is claimed is:
1. An extrusion molding apparatus for successively producing a
product having a wood pattern with a predetermined sectional shape
by feeding a thermoplastic synthetic resin to an extruder and
extruding the product through a die installed at an outlet of the
extruder, wherein a second inlet is formed at one side of the die
to fit a second synthetic resin thereinto, a second extruder which
feeds the second synthetic resin is connected to the second inlet,
and a second passage communicated with the second inlet of the die
is formed to communicate with an original synthetic resin passage
formed in the die, thereby coating. the second synthetic resin on a
surface of the product extruded from the die.
2. The extrusion molding apparatus of claim 1, wherein the second
passage of the die is formed to communicate with the original
synthetic resin passage so that the whole surface of the product is
coated with the second synthetic resin and a sectional area of the
second passage is irregularly formed, thereby forming the wood
pattern.
3. The extrusion molding apparatus of claim 1, wherein the second
synthetic resin fed from the second extruder contains a wood powder
of 80.about.120 meshes at a predetermined ratio.
4. An extrusion molding method for successively producing a product
having a wood pattern with a predetermined sectional shape by
feeding a thermoplastic synthetic resin to an extruder and
extruding the product through a die installed at an outlet of the
extruder, the extrusion molding method comprising the steps of:
forming a second passage in a synthetic resin passage formed in the
die to communicate with the synthetic resin passage; and connecting
a second extruder to the second passage so that the second
synthetic resin is coated on a surface of the product.
5. The extrusion molding method of claim 4, further comprising the
step of forming the second passage to communicate with an original
synthetic resin passage so that the whole surface of the product is
coated with the second synthetic resin.
6. The extrusion molding method of claim 5, further comprising the
step of irregularly forming a sectional area of the second passage
so that the second synthetic resin is fed to each portion of the
product at different ratios, thereby forming a wood pattern by the
second synthetic resin.
7. The extrusion molding method of claims 4, wherein the second
synthetic resin contains a wood powder of 80.about.120 meshes at a
predetermined ratio.
8. A product having a wood pattern characterized in that a second
synthetic resin is formed on an outer surface of the product
produced by extrusion molding, at different ratios depending on
positions.
9. The product having a wood pattern of claim 8, wherein the second
synthetic resin contains a wood powder of 80.about.120 meshes at a
predetermined ratio.
10. An extrusion molding die for a product having a wood pattern,
provided with a thermoplastic synthetic resin and a synthetic resin
passage, the thermoplastic synthetic resin being installed at an
outlet of an extruder so that it is to be fed to the extruder and
then extruded in the product having a predetermined sectional shape
such as the synthetic resin passage, the extrusion molding die
characterized in that a second inlet is formed at one side of the
die to fed a second synthetic resin thereto, and the second inlet
is formed to communicate with a second passage communicated with
the synthetic resin passage of the die so that the second synthetic
resin is coated on a surface of the product extruded from the
die.
11. The extrusion molding die of claim 10, wherein the second
passage is formed around the second synthetic resin passage so that
the whole surface of the product is coated with the second
synthetic resin.
12. The extrusion molding die of claim 11, wherein the second
passage is formed on the whole surface of the product at a constant
interval so that the second synthetic resin of a predetermined
ratio passes through the whole surface of the product.
13. The extrusion molding die of claim 11, wherein the second
passage includes a retainer communicated with the second inlet at
the outmost so that the second synthetic resin is introduced into
the second passage at a constant pressure.
14. The extrusion molding die of claim 13, wherein the second
passage includes a nozzle passage which is greater than a sectional
area of the second passage but smaller than a sectional area of the
retainer, the nozzle having one end communicated with the retainer
and the other end communicated with the synthetic resin
passage.
15. The extrusion molding die of claim 14, wherein the retainer and
the nozzle passage have a curved section.
16. The extrusion molding die of claim 14, wherein the nozzle
passage has a sectional area which is gradually reduced toward the
synthetic resin passage.
17. The extrusion molding die of claim 14, wherein the nozzle
passage is inclined at a predetermined angle along a flow of the
second synthetic resin.
18. The extrusion molding die of claims 10, wherein the second
synthetic resin contains a wood powder of 80.about.120 meshes at a
predetermined ratio.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an extrusion molding
apparatus and an extrusion molding method, and more particularly to
an extrusion molding apparatus for a product having a wood pattern
and an extrusion molding method thereof, in which a second
synthetic resin containing a wood powder of 80.about.120 meshes at
a predetermined ratio is fed to a die through a second extruder and
then is coated on a surface of the product extruded from the die,
thereby obtaining an esthetic surface and improving durability.
[0003] 2. Discussion of the Related Art
[0004] Generally, extrusion molding is to successively manufacture
products, such as pipes, rods, sheets, films, fibers, and coating
cables, by extruding a thermoplastic synthetic resin, which has
been heated and softened, from an extrusion die using an
extruder.
[0005] A conventional extrusion molding apparatus is configured to
wind or cut the product by placing a pellet shaped thermoplastic
synthetic resin in a hopper, softening it with a screw in a heating
cylinder, extruding it from the die, and cooling it. The
conventional extrusion molding apparatus is characterized in that a
softening resin is successively extruded with a screw. The products
having various sections may be made depending on shapes of holes of
an extrusion die at an outlet of an extruder. Such extrusion
molding is widely used in accordance with the development of
polymer compounds such as synthetic resin and has become a basis of
mass production.
[0006] Among the products based on the above-described extrusion
molding, there are the products having a constant section, such as
a window frame and a doorframe. These products are on a high-grade
trend to give an effect of raw lumber. If the product is
manufactured using a general synthetic resin, it is likely that the
product having a single color is manufactured. Therefore, the
product coated with a film, such as sheet with a wood pattern,
wood, and paper, to give an effect of raw lumber is recently coming
out in the market.
[0007] However, the product coated with such a film has several
problems. Since the film is made of a material and characteristics
different from those of the product, the film and the product
respectively have different shrinkage depending on temperature
changes. In this case, a problem arises in that it is likely to
take the film, such as sheet, wood, and paper, off the product as
time passes.
SUMMARY OF THE INVENTION
[0008] Accordingly, the present invention is directed to an
extrusion molding apparatus for a product having a wood pattern and
an extrusion molding method that substantially obviates one or more
of the problems due to limitations and disadvantages of the related
art.
[0009] An object of the present invention is to provide an
extrusion molding apparatus for a product having a wood pattern and
an extrusion molding method, in which a second synthetic resin
containing a wood powder of 80.about.120 meshes is coated on a
surface of the product at different ratios.
[0010] Additional features and advantages of the invention will be
set forth in the description which follows, and in part will be
apparent from the description, or may be learned by practice of the
invention. The objectives and other advantages of the invention
will be realized and attained by the scheme particularly pointed
out in the written description and claims hereof as well as the
appended drawings.
[0011] To achieve these and other advantages and in accordance with
the purpose of the present invention, as embodied and broadly
described, in an extrusion molding apparatus for successively
producing a product having a wood pattern with a predetermined
sectional shape by feeding a thermoplastic synthetic resin to an
extruder and extruding the product through a die installed at an
outlet of the extruder, it is characterized in that a second inlet
is formed at one side of the die to fit a second synthetic resin
thereinto, a second extruder which feeds the second synthetic resin
is connected to the second inlet, and a second passage communicated
with the second inlet of the die is formed to communicate with an
original synthetic resin passage formed in the die, thereby coating
the second synthetic resin on a surface of the product extruded
from the die.
[0012] In another aspect of the present invention, an extrusion
molding method for successively producing a product having a wood
pattern with a predetermined sectional shape by feeding a
thermoplastic synthetic resin to an extruder and extruding the
product through a die installed at an outlet of the extruder, the
extrusion molding method includes the steps of: forming a second
passage in a synthetic resin passage in the die to communicate with
the synthetic resin passage; and connecting a second extruder to
the second passage so that the second synthetic resin is coated on
a surface of the product extruded from the die.
[0013] In other aspect of the present invention, in an extrusion
molding die for a product having a wood pattern, provided with a
thermoplastic synthetic resin and a synthetic resin passage, the
thermoplastic synthetic resin being installed at an outlet of an
extruder so that it is to be fed to the extruder and then extruded
in the product having a predetermined sectional shape such as the
synthetic resin passage, a second inlet is formed at one side of
the die to fed a second synthetic resin thereto, and the second
inlet is formed to communicate with a second passage communicated
with the synthetic resin passage of the die so that the second
synthetic resin is coated on a surface of the product extruded from
the die.
[0014] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are intended to provide further explanation of
the invention as claimed.
BRIEF DESCRIPTION OF THE ATTACHED DRAWINGS
[0015] The invention will be described in detail with reference to
the following drawings in which like reference numerals refer to
like elements wherein:
[0016] FIG. 1 is a perspective view of a product manufactured by an
extrusion molding method according to the present invention;
[0017] FIG. 2 is a perspective view of an extrusion molding
apparatus according to the present invention;
[0018] FIG. 3 is a perspective view of a second extruder in an
extrusion molding apparatus according to the present invention;
[0019] FIG. 4 is a perspective view of an extrusion molding die
according to the present invention;
[0020] FIG. 5 is a front view of a second molding member which is a
part of the extrusion molding die according to the present
invention;
[0021] FIG. 6 is a sectional view taken along line IV-IV of FIG.
3;
[0022] FIG. 7 is a front view of a first molding member which is a
part of the extrusion molding die according to the present
invention;
[0023] FIG. 8 is a sectional view taken along line VI-VI of FIG.
5;
[0024] FIG. 9 is a sectional view taken along middle portions of
the first and second molding members, illustrating combination of
FIG. 4 and FIG. 6; and
[0025] FIG. 10 is a front view of a first molding member which is a
part of the extrusion molding die according to the present
invention, illustrating a feeding state of a second synthetic
resin.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Reference will now be made in detail to the preferred
embodiments of the present invention, examples of which are
illustrated in the accompanying drawings.
[0027] An extrusion molding product 1 according to the present
invention, as shown in FIG. 1, is configured such that an original
synthetic resin is coated with a second synthetic resin lb. The
second synthetic resin 1b contains a wood powder of 80.about.120
meshes and is coated on a surface of the original synthetic resin
at different ratios so that a wood pattern la is formed.
[0028] As shown in FIGS. 2 to 4, an extrusion molding apparatus for
manufacturing the aforementioned product 1 includes a first
extruder 100, a die 10 installed at an outlet of the first extruder
100, and a second extruder 200 installed at a side of the die
10.
[0029] The first extruder 100 has the same configuration as that of
a general extruder. That is, the first extruder 100 includes a heat
cylinder 101 provided with a heater 102 on an outer surface, a
hopper 103 for supplying a first thermoplastic synthetic resin to
an inner portion of the heat cylinder 101, a screw 104 for
extruding the first synthetic resin softened by heat in the heat
cylinder 101 to the die 10 by rotation, and a driver 110 for
driving the screw 104.
[0030] Likewise, the second extruder 200 has the same configuration
as that of a general extruder. The second extruder 200 includes a
heat cylinder 201 provided with a heater 202, a hopper 203, a screw
(not shown), and a driver 210. The hopper 203 is supplied with a
second synthetic resin which contains a wood powder of 80.about.120
meshes to form a wood pattern 1a on a surface of the product 1 to
be extruded.
[0031] The die 10 connected with the first and second extruders 100
and 200, as shown in FIGS. 4 to 10, includes first synthetic resin
passages 21 and 31 for extruding the first synthetic resin. The
second extruder 200 is connected between two moldings 20 and 30
coupled to each other at the foremost among a plurality of moldings
constituting the die 10. The second synthetic resin is fed between
the two moldings and then is extruded along a passage formed to
communicate with the first synthetic resin passages 21 and 31.
Since the second synthetic resin passage is extruded around the
first synthetic resin passages 21 and 31 by the above structure,
the second synthetic resin is coated on the first synthetic resin
passages 21 and 31 constituting the product 1. Since the second
synthetic resin contains a wood power of 80.about.120 meshes, a
wood pattern 1a is formed on a surface of the product 1.
[0032] The wood pattern 1a is distinctly formed on the surface of
the product 1 by the two moldings 20 and 30 at the end among the
moldings of the die 10. That is, a connecting passage 40 is formed
between the second molding member 20 at the end of the die 10 and
the first molding member 30 next to the second molding member 20.
The second synthetic resin containing a wood powder formed by
grinding wood is fed to the connecting passage 40. The connecting
passage 40 is connected with the second extruder 200. The second
synthetic resin which passed through the connecting rod 40 moves to
the synthetic resin passages 21 and 31 along a passage formed
inside the first and second molding members 20 and 30 and is coated
on the surface of the synthetic resin extruded by pressure of the
first extruder.
[0033] The first molding member 30, as shown in FIGS. 4 to 6 and
FIG. 9, includes half of the connecting passage 40 having a screw
for connecting to the second extruder. The synthetic resin passage
31 is formed inside the first molding member 30, and a slit surface
32 is formed around the synthetic resin passage 31 at a height
lower than a surface of the first molding member 30 so that the
second synthetic resin flows to the synthetic resin passage 31. A
retainer groove 30 connected to the connecting passage 40 is formed
around the slit surface 32. The retainer groove 33 is lower then
the slit surface 32. Therefore, after the second synthetic resin is
completely filled in the retainer groove 33, it passes through the
slit surface 32 toward the synthetic resin passage 31 by pressure
of the second synthetic resin and then extruded through the whole
surface.
[0034] The second molding member 20, as shown in FIG. 4, and FIGS.
7 to 9, is symmetrically formed to engage with the first molding
member 30. Half of the connecting passage 40 having a screw for
connecting with the second extruder is formed in the second molding
member 20 so that the complete connecting passage 40 is formed
together with the connecting passage 40 formed in the first molding
member 30. In the same manner as the first molding member 30, the
synthetic resin passage 21 is formed in the second molding member
20. A lead surface 22 is formed around the synthetic resin passage
21 together with the slit surface 32, thereby forming a space where
the second synthetic resin flows. A retainer groove 23 connected to
the retainer groove 33 of the first molding member 30 is formed
around the lead surface 22. Particularly, the second molding member
20, as shown in FIGS. 7 to 9, includes a plurality of nozzle
grooves 24 formed with a curved section, which is higher than the
retainer groove 23 but lower than the lead surface 22, between the
retainer groove 23 and the synthetic resin passage 21. Each of the
nozzle grooves 24 includes a distal end 24a supplied with the
second synthetic resin at a greater amount than that supplied to
any other portions, thereby forming a wood pattern. The distal end
24a has a sectional area smaller than that of any other portions to
serve as a nozzle. The nozzle grooves 24 are inclined at a
predetermined angle along an incoming direction of the second
synthetic resin so that the second synthetic resin readily moves to
the nozzle grooves 24 through the retainer groove 23.
[0035] The retainer grooves 23 and 33 of the first and second
molding members 20 and 30, as shown in FIG. 9, are formed to
surround the synthetic resin passages 21 and 31 and have a curved
section with a predetermined gradient.
[0036] FIG. 9 is a sectional view illustrating a coupling state of
the first and second molding members 20 and 30. As shown in FIG. 9,
the second synthetic resin is introduced into the retainer grooves
23 and 33 through the connecting passage 40 and then moves to the
synthetic resin passages 21 and 31 through the space between the
slit surface 32 and the lead surface 22. Particularly, as shown in
FIG. 7, since the portion where the nozzle grooves 24 are formed
has a greater passage area than any other portions, the second
synthetic resin moves at a greater amount, thereby resulting in
that a wood pattern 1a is formed on the surface of the product
1.
[0037] The operation of the aforementioned extrusion molding
apparatus will now be described based on the flow of the first and
second synthetic resins.
[0038] First, the first synthetic resin, as shown in FIGS. 2 and 3,
is fed to the first extruder 101 through the hopper 103 and moves
to the die 10 by pressure of the rotating screw 104. At this time,
the first synthetic resin moves while being softened by the heater
102. The first synthetic resin moved to the die 10 by the screw 104
is extruded in accordance with shapes of the first synthetic resin
passages 21 and 31 formed in the die 10, so that the product 1 is
successively produced.
[0039] The aforementioned extrusion method is the same as the
operation of the typical extrusion molding apparatus. In addition
to the above method, in the present invention, the second synthetic
resin containing a wood powder of 80.about.120 meshes, as shown in
FIGS. 2 and 3, is fed to the second extruder 200 through the hopper
203 and moves through the screw and the second passage 40 formed at
a side of the die 10 while being-softened by the heater 202. The
second synthetic resin introduced into the side between the first
and second molding members 20 and 30, as shown in FIG. 9, is
introduced around the first synthetic resin passages 21 and 31
through the space formed by the retainer grooves 23 and 33 of the
first and second molding members 20 and 30. At this time, the
second synthetic resin is also introduced into the space formed by
the nozzle grooves 24 and the slit surface 32. Afterwards, the
second synthetic resin is fed to the distal end 24a of the nozzle
groove 24 and at the same time moves to the surface of the first
synthetic resin extruded through the space formed by the slit
surface 32 and the lead surface 22. Therefore, the first synthetic
resin is coated with the second synthetic resin. At this time,
since the second synthetic resin extruded through the nozzle
grooves 24 has a greater amount, the wood pattern 1a is formed on
the surface of the product 1.
[0040] The operation of the first and second molding members 20 and
30 will be described in more detail.
[0041] The second extruder is connected to the first and second
molding members 20 and 30 through the connecting passage 40 so that
the second synthetic resin containing a wood powder is fed to the
first and second molding members 20 and 30. The second synthetic
resin, as shown in FIG. 9, is fed to the retainer grooves 23 and 33
of the first and second molding members 20 and 30. At this time,
the nozzle grooves 24 are inclined at a predetermined angle along a
flow of the second synthetic resin introduced into the retainer
grooves 23 and 33. Accordingly, the second synthetic resin is also
fed to the nozzle grooves 24. Once the second synthetic resin is
fully filled in the retainer grooves 23 and 33, the second
synthetic. resin moves to the whole surface of the synthetic resin
passages 21 and 31 through the space, which is formed by the slit
surface 32 and the lead surface 22, by the pressure of the second
extruder. As a result, the synthetic resin moving through the whole
surface of the synthetic resin passages 21 and 31 is coated with
the second synthetic resin. At this time, since the second
synthetic resin moves to the space formed by the nozzle grooves 24
and the slit surface 32 at a greater amount, the wood pattern 1a is
formed on the surface of the product 1. That is, as shown in FIG.
10, the wood pattern la is formed on lower and upper surfaces of
the product 1.
[0042] The second synthetic resin contains, a wood powder obtained
by grinding wood as described above. However, the second synthetic
resin may be formed of other materials as the case may be.
[0043] Furthermore, the retainer grooves 23 and 33 are formed to
surround the synthetic resin passages 21 and 31 so that the whole
surface of the synthetic resin is equally coated with the second
synthetic resin. That is, at a portion close to the connecting
passage 40 supplied with the second synthetic resin, the retainer
grooves 23 and 33 are formed far away from the synthetic resin
passages 21 and 31. By contrast, at a portion far away from the
connecting passage 40, the retainer grooves 23 and 33 are formed
close to the synthetic resin passages 21 and 31. Also, it should be
noted that the retainer grooves 23 and 33 are bent depending on
sectional shapes of the synthetic resin passages 21 and 31.
[0044] Furthermore, even if a molding member is designed by
considering various cases, the second synthetic resin is introduced
into the synthetic resin passages 21 and 31 at different ratios
depending on position. In this case, some wood pattern may
naturally be formed. However, in the present invention, since the
nozzle grooves 24 are formed, accurate wood pattern can
artificially be formed.
[0045] As described above, the extrusion molding apparatus for a
product having a wood pattern and the extrusion molding method
according to the present invention have the following
advantages.
[0046] Since the product having a wood pattern is formed by the
first and second synthetic resins, the wood pattern is not taken
off and esthetic appearance can be obtained.
[0047] In addition, the finished product is manufactured by one
time process, and no process of wrapping a sheet paper of a wood
pattern is required. This reduces the process steps and thus
enhances the productivity.
[0048] The foregoing embodiments are merely exemplary and are not
to be construed as limiting the present invention. The present
teachings can be readily applied to other types of apparatuses. The
description of the present invention is intended to be
illustrative, and not to limit the scope of the claims. Many
alternatives, modifications, and variations will be apparent to
those skilled in the art.
* * * * *