Manufacturing of Mechanical Supporting Foamed Sheets by processing Free Flowing Phenolic Molding Compounds with the Foam Extrusion and its Characterization

The press-section of a paper machine holds several different types of press rolls. One of the many press roll variants is the Valmet produced press roll, ViscoNip. This press roll utilizes an extended nip in order to increase the amount of water removed. The extended press nip in ViscoNip is special since it is controllable by a pressurized polyurethane press shoe. The press shoe runs through the body of the press roll. Due to the limits of the current production process, new manufacturing methods and construction solutions are needed. In cooperation with another thesis, the current design and manufacturing process was reviewed and a plan intended to improve the current solution was formulated. The plan was to, by working together in a project, perform a product development process intended to create concepts able to utilize new methods of manufacturing. By using established methods of concept generation, such as Brainwriting 6-3-5, 11 concepts were created. Some of these concepts involved a redesign of the press shoe, leading to a need for construction and performance analysis. The other thesis focusing on the structural and mechanical performance evaluation of the new concepts. The work of this thesis focusing on researching new possible and available manufacturing solutions. The new concepts were analyzed with new and possible manufacturing methods to fulfill all the requirements. With all data, a document was created and market research was made to get feedback from more knowledgeable in the subject. Moreover, sequence analysis between the concepts with the current and those new manufacturing methods was made to further explain which manufacturing method that could solve the main problem. All in all, one different redesigned concept was deemed as having potential for further development. The current solution was also deemed as having potential for future development but only when new manufacturing methods or techniques were considered.

This thesis is focused on the construction of punching device for punching continuously extruded plastic profile. This device is part of a larger production line. The theoretical part of this work will be focused in an introduction to plastic extrusion, cutting, molding properties and market research with punched plastic profiles. The practical part will deal with the product description, production line and the structural design of the entire machine itself including calculations. Part of this work are also drawing of selected parts and a 3D model.