Polycarbonate Profile
Customer Demand
- Customer Background: Customer is a contractor working on a tender project.
- Scene Description: The product will be used on a factory roof.
- Demand portrait: polycarbonate hollow sheets.
WeProFab Primary Solution
- Processes: The panel is extruded sheets. We customized the sheet based on the customers’ requirement .There are accessieries such as weatherproof sealing tape, plastic end caps, T-type fasteners for assembly.
- Raw materials: polycarbonate sheets, tape, end caps, fasteners
WeProFab Final Solution
- Processes descriptions: The panels are extruded sheets produced by the factory using molds. These are matched with accessories such as weatherproof sealing tape, I-beams, plastic end caps, and T-type fasteners for assembly.
- Critical to Quality: The key challenge involves integrating the customer’s design drawings and installation plan with the factory’s existing solutions and compatible accessories to form a cohesive package.
- Final products description: The final deliverable is a complete solution package, including the hollow sheets and all necessary matching accessories as an integrated product offering.
| Key Difficulty | Phenomenon Description | Main Causes | Consequences |
| Severe Heat Accumulation | The heat generated by material shear in the barrel far exceeds its dissipation rate, leading to excessively high melt temperature. | Plastics are poor thermal conductors. G reater wall thickness results in longer heat dissipation paths from the core, making heat accumulation more likely. | Material degradation (molecular chain breakage), decreased mechanical properties, and surface defects like scorching or bubbles. |
| Uneven Cooling & Internal Stress | The outer surface cools and solidifies first, while the inner core remains molten. Subsequent cooling and contraction of the core can create negative pressure, leading to shrinkage voids or vacuum bubbles. | The cooling system acts primarily on the product’s surface, creating a significant difference in cooling rates between the interior and exterior. | Internal stress within the product, causing warpage, deformation, or even brittle failure during use. |
| Reduced Extrusion Speed | To prevent melt fracture and thermal degradation, the screw speed must be lowered, resulting in very slow production line speeds (as low as 0.04-0.08 m/min). | This is a direct result of managing heat accumulation and ensuring sufficient cooling time. | Significant decrease in production efficiency and a notable increase in production costs. |
| Difficulties in Sizing and Haul-off | The increased weight of the thick-wall pipe makes it more prone to sagging (drawdown) in the vacuum sizing tank before it fully solidifies, leading to uneven wall thickness (thinner at the top, thicker at the bottom). | The product lacks sufficient stiffness and strength before it is completely cooled and set. | Poor control over product dimensional accuracy, roundness, and wall thickness uniformity. |
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