Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(Section 10 and Rule 13)

1. TITLE OF THE INVENTION:
APPARATUS AND METHOD FOR OPTIMIZING THE OUTER DIAMETER OF AN EXTRUDED TUBE

2. APPLICANT:
Meril Life Sciences Pvt. Ltd., an Indian company of the address Survey No. 135/139 Bilakhia House, Muktanand Marg, Chala, Vapi-Gujarat 396191, India.

The following specification particularly describes the invention and the manner in which it is to be performed:

 
FIELD OF INVENTION
[001] The present invention relates to processing of extruded tubes. More specifically, the present invention pertains to an apparatus and a method for optimizing the of the outer diameter of an extruded tube.
BACKGROUND OF INVENTION
[002] Medical tubes, including catheters, intravenous (IV) lines, and other precision tubing used in healthcare applications, must adhere to strict dimensions to ensure safety, compatibility, and optimal functionality. These tubes are typically produced using extrusion processes, efficiently achieving general dimensional consistency. However, in high-precision medical applications, extruded tubes often exhibit variations in their outer diameter (OD) that fall outside the stringent dimensions prescribed for critical medical devices. Even a slight deviation in diameter can lead to significant functional issues when the tube interfaces with one or more other components, such as connectors, fittings, or insertion devices. These discrepancies can impair device performance, complicate secure connections, and potentially result in leakage, mechanical failure, or compromised patient safety.
[003] Conventional extrusion processes often fail to deliver the level of precision necessary for applications where tight adherence to prescribed dimensions are essential. To address these discrepancies, secondary machining techniques, such as centerless grinding or machining, are commonly employed. However, these traditional methods present notable challenges when applied to medical tubing. Since medical tubes are typically made from soft or flexible biocompatible materials, they are prone to deformation, surface damage, or stress cracking when subjected to mechanical forces involved in these machining operations. Furthermore, these additional processing steps introduce risks of contamination, including particulates or micro-cracks, which can compromise the structural integrity and biocompatibility of the tubes. In medical applications, even the smallest surface defects or contamination can pose serious risks to patient safety and the overall functionality of the medical device.
[004] Thus, there arises a need for an apparatus and method that overcomes the problems associated with the conventional extrusion line.
SUMMARY OF INVENTION
[005] The present invention relates to an apparatus for optimizing the outer diameter of an extruded tube. The apparatus includes a platform and an optimizing assembly mounted on the platform. The optimizing assembly includes a base plate, a holder mounted on the base plate, and at least one die coupled to the holder. The die includes a lumen adapted to receive a workpiece. The apparatus includes a heater mounted on the base plate and thermally coupled to the die. The heater configured to heat the die to a pre-defined temperature. One of the optimizing assembly or the workpiece is movable with respect to the other. The die is configured to optimize the outer diameter of the workpiece upon application of heat and movement of one of the optimizing assembly or the workpiece.
[006] The foregoing features and other features as well as the advantages of the invention, will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[007] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the apportioned drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale.
[008] Fig. 1 depicts a perspective view of an apparatus 100 along with a workpiece 150, in accordance with an embodiment of the present disclosure.
[009] Fig. 2A depicts a perspective view of the workpiece 150, in accordance with an embodiment of the present disclosure.
[0010] Fig. 2B depicts a cross-sectional view of the workpiece 150, in accordance with an embodiment of the present disclosure.
[0011] Fig. 3A depicts a perspective view of an extruded tube 152 of the workpiece 150, in accordance with an embodiment of the present disclosure.
[0012] Fig. 3B depicts a cross-sectional view of the extruded tube 152 of the workpiece 150, in accordance with an embodiment of the present disclosure.
[0013] Figs. 4A, 4B, and 4C depict various views of a die 126 of the apparatus 100, in accordance with an embodiment of the present disclosure.
[0014] Figs. 5A, 5B, and 5C depict various views of the assembly of the die 126 and the workpiece 150, in accordance with an embodiment of the present disclosure.
[0015] Fig. 6A depicts a perspective view of an optimizing assembly 120 of the apparatus 100, along with the workpiece 150, in accordance with an embodiment of the present disclosure.
[0016] Fig. 6B depicts a side view of the optimizing assembly 120 of the apparatus 100, along with the workpiece 150, in accordance with an embodiment of the present disclosure.
[0017] Fig. 7 depicts a flowchart of a method 700 for optimizing diameter of the extruded tube using the apparatus 100, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0018] Prior to describing the invention in detail, definitions of certain words or phrases used throughout this patent document will be defined: the terms "include" and "comprise", as well as derivatives thereof, mean inclusion without limitation; the term "or" is inclusive, meaning and/or; the phrases "coupled with" and "associated therewith", as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have a property of, or the like; Definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.
[0019] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
[0020] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that the disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed herein. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses.
[0021] Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages of the embodiments will become more fully apparent from the following description and apportioned claims, or may be learned by the practice of embodiments as set forth hereinafter.
[0022] The present disclosure relates to an apparatus for optimizing the outer diameter of an extruded tube, particularly a medical tube, where high dimensional precision is critical. Variations in outer diameter, however small, can significantly affect the performance, compatibility, and regulatory compliance of the medical tube. To address these challenges, the apparatus employs an optimizing assembly designed to finely adjust the tube’s outer dimensions after extrusion. This optimizing assembly utilizes a combination of a heater and a die, which are thermally and mechanically configured to work in coordination. The die includes a cavity through which the tube passes, while the heater applies controlled thermal energy to selectively soften the tube material as the tube progresses through the die. The die is dimensioned to incrementally reshape the outer surface of the tube and is adapted to accommodate the tube in conjunction with a centrally positioned mandrel, which provides internal support to maintain lumen integrity during the reshaping process.
[0023] The apparatus is configured to facilitate uniform radial compression and ensure that the tube retains its structural and functional characteristics while undergoing dimensional change. The apparatus thus enables precision tuning of the outer diameter under thermomechanical control, resulting in improved product consistency, reduced material stress, and enhanced quality suitable for demanding applications such as catheter shafts, infusion lines, and other critical medical tubing.
[0024] Referring now to the figures, Fig. 1 depicts a perspective view of an apparatus 100 in conjunction with a workpiece 150, in accordance with an embodiment of the present disclosure. The apparatus 100 is configured to optimize the outer diameter of the workpiece 150. In an embodiment, the apparatus 100 is configured to optimize the outer diameter of an extruded tube 152 of the workpiece 150. In an embodiment, the apparatus 100 has a first end 100a and a second end 100b. The apparatus 100 includes a platform 110, a clamp 112, an optimizing assembly 120, at least one die 126, and a heater 130. In an embodiment, one of the optimizing assembly 120 or the workpiece 150 is movable with respect to the other.
[0025] The platform 110 serves as the structural base for the apparatus 100 and is configured to ensure stable and precise operation of the optimizing assembly 120. In an exemplary embodiment, the platform 110 may be implemented as a conveyor system to facilitate the automated or semi-automated movement of the optimizing assembly 120 into and out of the processing position. The processing position refers to a designated location along the platform 110 at which the optimizing assembly 120 performs its intended operations on a workpiece 150, such as adjustment, alignment, or processing of material during the extrusion process. When configured as a conveyor, the platform 110 may include motorized rollers, belts, or chains that transport the optimizing assembly 120 along a defined path, aligning it accurately with the clamp 112. This conveyor-based configuration moves the optimizing assembly 120 back and forth. In another exemplary embodiment, the platform 110 is a stationary base. The platform 110 may be made from high-strength, wear-resistant materials to withstand industrial environments, absorb mechanical vibrations, and maintain structural integrity and alignment throughout the optimization process.
[0026] The clamp 112 is provided towards the first end 100a of the apparatus 100. The clamp 112 is configured to secure a first end 150a of the workpiece 150 in place. The clamp 112 thus ensures that the workpiece 150 remains firmly stationary thereby preventing any unintended movement, rotation, or slippage of the workpiece 150 during the optimization operation. As the clamp 112 holds the first end 150a of the workpiece 150 in place, accurate adjustment and measurement of the workpiece's 150 outer diameter is possible. The clamp 112 may be implemented in various configurations depending on the specific application and characteristics of the workpiece 150. The clamp 112 may comprise a mechanical jaw-type mechanism, a pneumatic or hydraulic actuation system, a collet-type clamp, a magnetically actuated (in cases involving ferromagnetic workpieces), etc. In an embodiment, the clamp 112 is a pneumatic actuation clamp system. Additionally or optionally, the clamp 112 may further include one or more integrated sensors to detect the presence, positioning, and/or clamping force applied to the workpiece 150, providing feedback to the apparatus 100 for enhanced reliability and safety during operation. In an embodiment, the apparatus 100 includes a sensor provided on the clamp 112 and configured to detect the presence, positioning, and/or clamping force applied to the workpiece 150.
[0027] Figs. 2A and 2B depict various views of the workpiece 150, in accordance with an embodiment of the present disclosure. The workpiece 150 includes the extruded tube (or tube) 152 and a mandrel 154. The mandrel 154 is inserted concentrically into a lumen 302 (shown in Fig. 3A) of the tube 152 to form the workpiece 150. The diameter of the mandrel 154 corresponds to the diameter of the lumen 302 of the tube 152 to ensure a snug fit for maintaining the circularity and dimensional accuracy of the tube 152 during an optimization operation. The mandrel 154 provides structural support to the tube 152 during the outer diameter optimization process and helps maintain concentricity, dimensional integrity, and smoothness of the final product.
[0028] The mandrel 154 may be made of stainless steel (SS), plastic, or any other suitable material. In an embodiment, the mandrel 154 is made of stainless steel (SS). In an embodiment, the mandrel 154 is coated with polytetrafluoroethylene (PTFE). The application of the PTFE coating on the stainless-steel mandrel 154 facilitates smooth insertion of the mandrel 154 into the tube 152 without causing abrasion, deformation, or other damage to the surface of the lumen 302 of the tube 152. Additionally, the PTFE coating ensures easy and damage-free removal of the mandrel 154 from the tube 152 once processing is complete, further improving efficiency and reducing the risk of contamination or internal surface defects.
[0029] Figs. 3A and 3B depict the tube 152 of the workpiece 150. The tube 152 is an extruded cylindrical structure designed for high-precision applications. The tube 152 may be made from a variety of materials, such as polymers, metals, or composites, depending on the intended use, with polymeric materials like PTFE, FEP, or nylon being common for applications requiring chemical resistance, flexibility, or insulation. The tube 152 is characterized by a uniform wall thickness, a smooth inner surface, and a consistent lumen 302, which is critical for mating precisely with the mandrel 154. The lumen 302 must be free from irregularities or defects, as it interfaces directly with the mandrel 154 during insertion.
[0030] Figs. 4A, 4B, and 4C depict various views of a die 126 of the apparatus 100, in accordance with an embodiment of the present disclosure. The die 126 is configured to optimize the outer diameter of the workpiece 150 upon application of heat and movement of one of the optimizing assembly 120 or the workpiece 150. The die 126 has a first end 126a and a second end 126b. The die 126 is an elongated member that has a lumen 602 extending from the first end 126a to the second end 126b of the die 126. The lumen 602 is adapted to receive the workpiece 150. In an embodiment, the lumen 602 has a first portion 604 towards the first end 126a of the die 126, a second portion 606, and a third portion 608 towards the second end 126b of the die 126 as depicted in Fig. 4C. The first portion 604 of the lumen 602 has a conical profile which gradually decreases from the first end 126a to the second portion 606 of the lumen 602. The gradual decrease of the first portion 604 of the lumen 602 facilitates easy insertion and initial guidance of the workpiece 150 into the die 126. In an embodiment, the first portion 604 is configured to guide the workpiece 150. The conical profile of the first portion 604 ensures smooth alignment and centering of the workpiece 150.
[0031] The second portion 606 is provided between the first portion 604 and the third portion 608. The second portion 606 of the lumen 602 has a cylindrical profile with a constant inner diameter. The second portion 606 extends along a predetermined axial length and is configured to remove excess materials from the outer surface of the workpiece 150. The cylindrical surface of the second portion 606 refines and corrects the outer diameter of the tube 152, ensuring consistent and precise dimensional control. The second portion 606 is configured to improve the quality and uniformity of the extruded or drawn product. In an embodiment, the diameter of the second portion 606 is less than the outer diameter of the workpiece 150.
[0032] The third portion 608 of the lumen 602 has a conical profile which gradually decreases from the second end 126b to the second portion 606 of the lumen 602. The third portion 608 of the lumen 602 is configured to allow ejection of the workpiece 150, reducing friction and allowing for a smooth transition out of the die 126. Additionally, the conical profile may assist in light compression or final shaping, minimizing defects or deformation as the workpiece 150 exits the die 126. Each portion of the lumen 602 is configured with precise geometric transitions to ensure that the workpiece 150 experiences a controlled and consistent shaping process from entry to exit. This configuration enhances dimensional accuracy, reduces material stress, and improves the overall mechanical properties of the processed component.
[0033] The die 126 includes an annular ring 610 disposed at the first end 126a of the die 126. annular ring 610 is configured to prevent unintended longitudinal displacement of the die 126 during operation, ensuring consistent alignment and dimensional stability of the die 126 relative to the optimizing assembly 120.
[0034] Figs. 5A, 5B, and 5C depict various views of the assembly of the die 126 and the workpiece 150, in accordance with an embodiment of the present disclosure. the workpiece 150 is positioned such that a first portion and a second portion of the workpiece 150 extend through the lumen 602 of the die 126. The first portion corresponds to the optimized or post-processed segment of the extruded tube 152, which has undergone shaping, reduction, or calibration by the die 126. The second portion represents the original, pre-processed form of the extruded tube, prior to any modification by the die 126. This arrangement creates a transitional shaping zone within the lumen 602 of the die 126, enabling continuous or progressive processing of the tube 152 as it advances axially. The coaxial alignment of the die 126, the extruded tube 152, and the mandrel 154 ensures structural stability, geometric precision, and uniform material flow during processing. The design supports high-fidelity forming or extrusion operations where precise dimensional control of the tubular product is required.
[0035] Referring to Fig. 6A, which illustrates a perspective view, and Fig. 6B, which illustrates a side view of the optimizing assembly 120 of the apparatus 100, in conjunction with the workpiece 150, in accordance with an embodiment of the present disclosure. The optimizing assembly 120 (also referred to as "assembly 120") is mounted on the platform 110, which serves as a structural base for supporting and guiding the assembly 120. The assembly 120 is configured to perform adjustment and optimization of the outer diameter of the workpiece 150. This configuration of the optimizing assembly 120 involves reshaping or resizing the extruded tube 152 to ensure the workpiece 150 meets the desired dimensional standards of the extruded tube 152. The optimization process may be mechanical, thermal, or a combination thereof, depending on the design of the assembly 120. In an embodiment, the optimization process is a combination of thermal and mechanical processes.
[0036] The optimizing assembly 120 is configured to be either fixed in place or movable relative to the platform 110. In one embodiment, the assembly 120 is configured to move linearly along the platform 110. The movement may be powered by pneumatic cylinders, electric actuators, or servo-driven mechanisms, and guided by rails, linear bearings, or other support structures integrated into the platform 110. In another embodiment, the optimizing assembly 120 is stationary, fixed in a defined position on the platform 110. In such a configuration, the workpiece 150 is conveyed or pulled through the stationary optimizing assembly 120 by an external puller, which performs optimization of the outer diameter of the tube 152 as the workpiece 150 passes through. The selection between a movable or stationary configuration may depend on the specific processing requirements, production throughput, or space constraints of the apparatus 100. The structural integration of the optimizing assembly 120 with the platform 110 ensures mechanical stability, positional accuracy, and consistent engagement with the workpiece 150 during the optimization process. This contributes to enhanced product uniformity, reduced rework, and improved process efficiency.
[0037] In an embodiment, the assembly 120 includes a base plate 122, a holder 124, and a guide support 128. The holder 124 and the guide support 128 are disposed on the base plate 122. The base plate 122 is coupled to the platform 110 and serves as the structural foundation for supporting and aligning the various components of the assembly 120. The base plate 122 ensures that all components are held in fixed relative positions and provides a rigid mounting surface that maintains geometric stability during operation. The fixed relative position includes the preservation of orientation, alignment, and distance between the components, thereby preventing any undesired movement or displacement relative to one another. The base plate 122 may be fabricated from a high-strength, thermally stable material such as aluminum, steel, or a composite alloy to withstand mechanical loads, thermal cycling, and vibrational forces encountered during the optimization process.
[0038] The holder 124 is mounted on the base plate 122. In an embodiment, the holder 124 includes one or more slots 124a that are configured to secure corresponding dies 126. The slot 124a may be formed as a recess, groove, or channel, designed to match the external profile of the die 126 to ensure a press-fit. This configuration allows for easy insertion and removal of the die 126 while preventing unwanted movement or misalignment during operation.
[0039] The die 126 is coupled to the holder 124. In an embodiment, the die 126 is press-fitted within the slot 124a or recess formed in the holder 124, ensuring a secure and precise positioning during operation. In an embodiment, The guide support 128 is mounted on the base plate 122 and is aligned with the holder 124 along a longitudinal axis of the holder 124. The guide support 128 is configured to provide directional stability and axial alignment for the workpiece 150, as the workpiece 150 is advanced through the die 126 or the assembly 120 is advanced, during the outer diameter tolerance optimization process. The guide support 128 maintains the straightness and concentricity of the workpiece 150 path, and prevents deflection, bending, or misalignment that could compromise the dimensional accuracy of the finished product.
[0040] In an embodiment, the guide support 128 (Fig. 4A) includes one or more cavities 128a configured to receive the respective second ends 150b of workpieces 150. As depicted in Fig. 6A, one cavity 128a of the guide support 128 receives the second end 150b of one workpiece 150. The cavity 128a is configured to provide support to the workpiece 150. The dimension of the cavity 128a closely matches the outer diameter of the workpiece 150. The cavity 128a may also be equipped with wear-resistant liners or PTFE coatings to reduce friction and protect the tube 152 surface during passage. The guide support 128 is a rigid attachment to ensure that the guiding function remains consistent, even under thermal expansion or mechanical loads. The guide support 128 ensures that the workpiece 150 enters the die 126 in a stable and controlled manner, contributing to the repeatability and precision of the outer diameter optimization process.
[0041] As depicted in the figures, a plurality of dies 126 are press-fitted into corresponding slots 124a provided in the holder 124. In an embodiment, each die 126 is configured to accommodate a single workpiece 150, thereby enabling the apparatus 100 to process multiple workpieces 150 simultaneously when multiple dies 126 are installed. The press-fit arrangement ensures that each die 126 is securely retained within its respective slot 124a of the holder 124, maintaining precise alignment during operation and minimizing vibration or displacement. Further, the guide support 128 is positioned downstream of the dies 126 and is provided with a plurality of corresponding cavities 128a, each aligned with a respective die 126. These cavities 128a are dimensioned and positioned to receive and support the corresponding workpieces 150 as they enter the dies 126. The combined function of the holder 124, the dies 126, and the guide support 128 contributes to improved dimensional accuracy, reduced material waste, and increased overall throughput of the apparatus 100.
[0042] The heater 130 is mounted on the base plate 122 and thermally coupled to the die 126 and a control unit 114 of the apparatus 100. The heater 130 is configured to heat the die 126 at a predefined temperature. The heater 130 may include one or more heating elements, such as resistance wires, cartridge heaters, or PTC (positive temperature coefficient) heating modules, configured to produce consistent and uniform thermal output across a defined temperature range. In an embodiment, the heater 130 includes one or more heating elements (not shown) provided within the holder 124 and in contact with the die 126. The heating element is arranged in a thermally conductive relationship with the surrounding structure of the holder 124 to maximize heat transfer efficiency while minimizing energy loss. In particular, the heating element is positioned to heat the die 126.
[0043] The control unit 114 is configured to regulate the temperature of the die 126 based on the predefined temperature by modulating the electrical power supplied to the heating elements. This control may be based on closed-loop feedback from temperature sensors integrated within or near the heater 130, enabling real-time monitoring and adjustment of the thermal output. The control system may include temperature calibration routines, safety cutoffs, and overheat protection features to ensure the reliable and safe operation of the heater 130 during extended use. Additionally, or optionally, the heater 130 may include thermal insulation layers or housing elements to direct heat toward specific regions or components and prevent undesired heat dissipation to adjacent parts of the apparatus 100.
[0044] The apparatus 100 includes the control unit 114, a display unit 116, and at least one thermal sensor. The control unit 114 is operatively coupled to the display unit 116, the thermal sensor, and the heater 130. In an embodiment, the display unit 116 is mounted at a predefined position that ensures easy accessibility and visibility for an operator. The display unit 116 serves as an input interface that enables an operator to input or modify predefined parameters. In an embodiment, display unit 116 is configured to allow an operator to feed or modify the predefined temperatures. The display unit 116 may comprise, but is not limited to, a human-machine interface (HMI), touchscreen panel, or programmable logic controller (PLC)-based graphical interface, a touchscreen interface, a graphical LCD or LED panel, or an integrated control panel with physical buttons and indicators.
[0045] The thermal sensor is disposed within the holder 124 and in contact with the die 126. The thermal sensor is configured to monitor the temperature of the die 126. The control unit 114 is configured to regulate the temperature based on a predefined temperature. The control unit 114 is configured to receive temperature data from the sensor. The control unit 114 includes a processing unit (not shown) and a memory (not shown). The memory may include various types of storage, such as read-only memory (ROM), random-access memory (RAM), flash memory, or hard disk drives. These components collectively enable the control unit 114 to perform tasks such as monitoring temperature data, executing control logic, and generating alerts. In an embodiment, the memory is configured to store one or more predefined parameters, including one or more temperature threshold values and historical temperature data, etc.
[0046] The processing unit is configured to receive monitored temperature data from the die 126. The processing unit is configured to execute computer-readable instructions stored in the memory to identify any discrepancies or abnormalities in the temperature of the die 126 by comparing the sensor data with the predefined temperature value. The discrepancies or abnormalities include such as sudden temperature loss, temperature mismatches between the actual temperature and preconfigured temperature, or readings outside the expected range. Upon identifying, the processing unit sends a signal to the control unit 114 to regulate the temperature of the die 126 or the movement of the workpiece 150 or the movement of the optimizing assembly 120.
[0047] The working of the apparatus 100 is described below. Initially, the workpiece 150 is formed by inserting the mandrel 154 into the lumen 302 of the tube 152. This arrangement ensures dimensional integrity and concentric alignment between the mandrel 154 and the tube 152 as described above. The diameter of the workpiece 150 is greater than the diameter of the second portion 606 of the lumen 602. To facilitate insertion of the workpiece 150 into the die 126, the first end of the tube 152 is manually heated to soften or partially melt the first end of the extruded tube 152 using a flame or other heat source. This softened end allows the workpiece 150 to be manually inserted into the lumen 602 of the die 126. Once inserted, the die 126, along with the workpiece 150, is press-fitted into the corresponding slot 124a of the holder 124. The first end 150a of the workpiece 150 is then secured in position using the clamp 112, while the second end 150b is supported by the guide support 128 to ensure axial alignment and overall stability during processing. After the workpiece 150 is correctly positioned on the apparatus 100, the control unit 114 activates the heater 130, which in turn heats the die 126 to the predefined temperature. This heating step prepares the die 126 to optimize the outer diameter of the tube 152.
[0048] In one embodiment, the optimizing assembly 120 is configured to be movable along the platform 110. As the assembly 120 moves relative to the clamped workpiece 150, due to the difference in diameter between the second portion 606 of the lumen 602 and the outer diameter of the workpiece 150, the lumen 602 of the second portion 606 trims excess material from the outer surface of the tube 152. This process effectively refines the outer diameter of the tube 152 to fall within the desired range.
[0049] In another embodiment, the optimizing assembly 120 is fixed in place on the platform 110. Here, the workpiece 150 is gradually pushed or pulled through the lumen 602 of the die 126 either manually or through external mechanisms, enabling diameter optimization. As the workpiece 150 is pulled through the lumen 602 of the die 126, the workpiece 150 progresses into the second portion 606 of the lumen 602. Due to the difference in diameter between the second portion 606 of the lumen 602 and the outer diameter of the workpiece 150, the lumen 602 of the second portion 606 trims excess material from the outer surface of the tube 152 to fall within the desired range.
[0050] Further, in both embodiments, the third portion 608 facilitates smooth ejection of the workpiece 150 from the die 126 and may apply a light compressive action to enhance surface finish and ensure dimensional accuracy.
[0051] After the outer diameter of the tube 152 has been optimized through the die 126, the workpiece 150 is removed from the apparatus 100. First, the clamp 112 is released to free the first end 150a of the workpiece 150. The guide support 128 is then disengaged from the second end 150b of the workpiece 150, allowing for smooth withdrawal. The extruded tube 152, still enclosing the mandrel 154, is carefully extracted from the die 126, either manually or with the aid of an extraction mechanism. To separate the tube 152 from the mandrel 154, the low-friction PTFE coating on the mandrel 154 facilitates easy separation of the tube 152 by pulling or gently pushing the mandrel 154 out of the lumen 302. This separation process ensures that the inner diameter of the tube 152 remains intact while maintaining the concentricity and surface integrity achieved during optimization. The separated components can then be collected for further inspection or processing.
[0052] Fig. 7 depicts a flowchart of a method 700 for optimizing the outer diameter of the extruded tube 152 using the apparatus 100 as described below. At step 702, the die 126, along with the workpiece 150, is mounted on the optimizating assembly 120. The workpiece 150 comprises a tube 152 and a mandrel 154 inserted concentrically within a lumen 302 of the tube 152.
[0053] At step 704, once the die 126 and the workpiece 150 are mounted, a first end 150a of the workpiece 150 is securely held in position using a clamp 112 disposed towards a first end 100a of the apparatus 100. The clamp 112 is configured to prevent any unintended movement, rotation, or slippage of the workpiece 150 during the optimization process, thereby maintaining positional accuracy and structural stability.
[0054] At step 706, a control unit 114 activates a heater 130 to heat the die 126 to a predefined threshold temperature. The application of heat facilitates optimal interaction between the die 126 and the surface of the workpiece 150 by reducing material resistance and enabling smoother material flow during passage through the lumen 602.
[0055] At step 708, one of the optimizing assembly 120 or the workpiece 150 is caused to move relative to the other, such that the workpiece 150 is guided through the lumen 602 of the die 126. As the workpiece 150 progresses through the first conical portion , the cylindrical second portion 606, and the exit conical portion of the die 126, the outer diameter of the tube 152 is reshaped, resized, or corrected in accordance with predetermined dimensional specifications. This step results in the formation of an extruded tube 152 with an optimized and uniform outer diameter.
[0056] The apparatus provides a highly effective solution for optimizing the outer diameter of the extruded tubes. The apparatus utilizes a die integrated into a controlled heating and the optimizing assembly to optimize the outer diameter while maintaining uniformity and surface integrity. The die, composed of the first portion, a second portion or resizing portion, and a third portion, facilitates smooth material entry, accurate outer diameter reduction, and stable exit of the tube. The use of a PTFE-coated stainless-steel mandrel supports the internal structure of the tube during the optimizing process, preventing deformation and allowing for easy insertion and removal without damaging the inner surface. The heating unit ensures that the die reaches the predefined temperature for material pliability, enhancing the efficiency of the stretching process and minimizing mechanical resistance. The guided alignment using the tube guide and conveyor maintains axial precision, reducing the risk of buckling or misalignment during processing. The apparatus enables reliable, repeatable production of tubes with significantly tighter OD, improved surface finish, and minimal post-processing, making it ideal for high-precision applications in medical, aerospace, and industrial tubing industries.
[0057] The scope of the invention is only limited by the appended patent claims. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. , C , Claims:WE CLAIM
1. An apparatus (100) for optimizing the outer diameter of an extruded tube (152), the apparatus (100) comprising:
a. an optimizing assembly (120) mounted on a platform (110), the optimizing assembly (120) comprising:
i. a base plate (122);
ii. a holder (124) mounted on the base plate (122);
b. at least one die (126) coupled to the holder (124), the die (126) includes a lumen (602) adapted to receive a workpiece (150);
c. a heater (130) mounted on the base plate (122) and thermally coupled to the die (126), the heater (130) configured to heat the die (126) to a pre-defined temperature;
d. wherein one of the optimizing assembly (120) or the workpiece (150) is movable with respect to the other; and
e. wherein the die (126) is configured to optimize the outer diameter of the workpiece (150) upon application of heat and movement of one of the optimizing assembly (120) or the workpiece (150).
2. The apparatus (100) as claimed in claim 1, wherein the optimizing assembly (120) is configured to be either fixed in place or movable relative to the platform (110).
3. The apparatus (100) as claimed in claim 1, wherein the workpiece (150) includes a mandrel (154) and an extruded tube (152), the mandrel (154) being coated with polytetrafluoroethylene (PTFE) and inserted into a lumen (302) of the extruded tube (152).
4. The apparatus (100) as claimed in claim 1, wherein the holder (124) comprises one or more slots (124a) configured to secure the corresponding die (126).
5. The apparatus (100) as claimed in claim 1, wherein the apparatus (100) comprises a clamp (112) configured to secure a first end (150a) of the workpiece (150).
6. The apparatus (100) as claimed in claim 5, wherein the apparatus (100) comprises a sensor provided on the clamp (112) and configured to detect the presence, positioning, and/or clamping force applied to the workpiece (150).
7. The apparatus (100) as claimed in claim 1, wherein the optimizing assembly (120) comprises a guide support (128) mounted on the base plate (122), the guide support (128) includes one or more cavities (128a) configured to receive second ends (150b) of the corresponding workpieces (150).
8. The apparatus (100) as claimed in claim 1, wherein the heater (130) comprises a plurality of heating elements provided within the holder (124) and in contact with the die (126).
9. The apparatus (100) as claimed in claim 1, wherein the lumen (602) of the die (126) comprises a first portion (604), a second portion (606), and a third portion (608), wherein:
a. the first portion (604) provided towards a first end (126a) of the die (126) configured to guide the workpiece (150);
b. the second portion (606) provided between the first portion (604) and the third portion (608) and configured to remove excess materials from an outer surface of the workpiece (150); and
c. wherein the third portion (608) provided towards a second end (126b) of the die (126) is configured to allow ejection of the workpiece (150).
10. The apparatus (100) as claimed in claim 9, wherein the second portion (606) of the lumen (602) has a cylindrical profile with a constant inner diameter.
11. The apparatus (100) as claimed in claim 1, wherein the apparatus (100) comprises one or more thermal sensors disposed within the holder (124) and in contact with the die (126), the thermal sensor is configured to monitor the temperature of the die (126).
12. The apparatus (100) as claimed in claim 1, wherein the apparatus (100) comprises:
a. a display unit (116) configured to allow an operator to feed or modify the predefined temperatures; and
b. a control unit (114) configured to regulate the temperature of the die (126) based on the predefined temperature.
c. wherein the control unit (114) is configured to regulate the temperature by modulating the electrical power supplied to the heating elements.
13. A method (700) for optimizing the outer diameter of an extruded tube (152), the method (700) comprising:
a. mounting, a die (126) along with a workpiece (150) on an optimizing assembly (120);
b. securing, a first end (150a) of the workpiece (150) using a clamp (112);
c. activating, a heater (130) to heat the die (126) to a predefined temperature; and
d. moving, one of the optimizing assembly (120) or the workpiece (150) relative to the other, such that the workpiece (150) passes through a lumen (602) of the die (126), thereby optimizing the outer diameter of the workpiece (150).
14. The apparatus (100) as claimed in claim 1, wherein a first end of the extruded tube (152) is manually heated to soften or partially melt the first end of the extruded tube (152).