An energy-saving fast-cycle blister box vacuum forming process

Abstract

The invention discloses an energy-saving rapid-cycle blister box vacuum forming process, which adopts a segmented heating device to adjust the heating power according to the thickness of the plastic sheet and the preheating temperature, thereby reducing energy consumption; uses a high-efficiency vacuum pump to increase the vacuum adsorption speed and shorten the forming cycle; optimizes the mold design to increase the heat transfer efficiency and reduce the cooling or heating time; adopts a rapid-cycle water cooling system to reduce the cooling water temperature and increase the cooling speed, thereby solving the problems of high energy consumption, long forming cycle and low production efficiency in the prior art.

Description

Technical Field

[0001] The invention relates to the technical field of plastic forming technology, in particular to an energy-saving fast-cycle blister box vacuum forming technology. Background Art

[0002] The existing vacuum forming process is widely used in the production of various plastic products, such as blister boxes, plastic containers, etc.

[0003] However, the existing vacuum forming process generally has the problems of high energy consumption, long forming cycle, low production efficiency, etc. Therefore, it is of great practical value to develop an energy-saving fast-cycle blister box vacuum forming process to solve the above problems. Summary of the invention

[0004] The purpose of this section is to summarize some aspects of embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the specification abstract and the invention title of this application to avoid blurring the purpose of this section, the specification abstract and the invention title, and such simplifications or omissions cannot be used to limit the scope of the present invention.

[0005] In view of the above problems existing in the existing vacuum forming process, the present invention is proposed.

[0006] Therefore, the technical problem solved by the present invention is to solve the problems of high energy consumption, long molding cycle and low production efficiency in the prior art.

[0007] In order to solve the above technical problems, the present invention provides the following technical solutions: an energy-saving fast-cycle blister box vacuum forming process, which is prepared by the following steps: S1: placing a plastic sheet on a heating device for preheating, and the preheating temperature is controlled within a range of 5 to 10°C lower than the melting point of the plastic; S2: placing the preheated plastic sheet on a mold, starting a vacuum pump, and extracting the air in the mold to allow the plastic sheet to be adsorbed on the mold; S3: cooling or heating the mold to allow the plastic sheet to reach a predetermined forming temperature in a short time, and then applying pressure to allow the plastic sheet to fit tightly in the mold to form a desired product shape; S4: taking the molded product out of the mold.

[0008] As a preferred solution of the energy-saving fast-cycle blister box vacuum forming process described in the present invention, a segmented heating device is used, the preheating temperature is 80°C, and the preheating time is 2 minutes; a high-efficiency vacuum pump is used, and the vacuum adsorption time is 1 second; the mold design is optimized, and the cooling time is 10 seconds; a fast-cycle water cooling system is used, and the cooling water temperature is 15°C.

[0009] As a preferred solution of the energy-saving fast-cycle blister box vacuum forming process described in the present invention, a segmented heating device is used, the preheating temperature is 85°C, and the preheating time is 3 minutes; a high-efficiency vacuum pump is used, and the vacuum adsorption time is 1.5 seconds; the mold design is optimized, and the cooling time is 12 seconds; a fast-cycle water cooling system is used, and the cooling water temperature is 18°C.

[0010] As a preferred solution of the energy-saving fast-cycle blister box vacuum forming process of the present invention, wherein: in step S1, when the plastic sheet is placed on the heating device for preheating, the heating time is determined according to the thickness of the plastic sheet and the preheating temperature, which is specifically achieved by the following formula:

[0011]

[0012] Where t is the heating time, s; k is the proportional constant, which is determined according to the specific characteristics of the plastic material. For polyethylene plastic, k is defined as 0.864; h is the thickness of the plastic sheet, mm; T preheat is the preheating temperature, °C; T room is room temperature, ℃; T melting is the melting point of the plastic, ℃.

[0013] As a preferred solution of the energy-saving fast-cycle blister box vacuum forming process of the present invention, wherein: in step S3, the applied pressure is 100-120N.

[0014] As a preferred solution of the energy-saving fast-cycle blister box vacuum forming process described in the present invention, wherein: the preheated plastic sheet is placed in front of the mold, and the molding mold needs to be cleaned to ensure the cleanliness of the mold surface; wherein, wet cleaning is first adopted during the cleaning process, and then dry cleaning is adopted; wherein, ethanol solvent is used for wet cleaning; wherein, air blowing and vacuum cleaning are used for dry cleaning.

[0015] As a preferred solution of the energy-saving fast-cycle blister box vacuum forming process described in the present invention, the preheated plastic sheet is placed in front of the mold, and the mold surface is pretreated; wherein the pretreatment step is specifically as follows: step one: applying the Fe3O4 coating to the mold surface; step two: standing for more than 30 minutes, after the Fe3O4 coating is firmly bonded to the mold surface, the preheated plastic sheet is placed in the forming mold.

[0016] As a preferred solution of the energy-saving fast-cycle blister box vacuum forming process described in the present invention, the coating thickness of the Fe3O4 coating is less than 1 mm.

[0017] The beneficial effects of the invention are as follows: the invention provides an energy-saving rapid-cycle blister box vacuum forming process, adopts a segmented heating device, realizes adjustment of the heating power according to the thickness of the plastic sheet and the preheating temperature, and reduces energy consumption; uses a high-efficiency vacuum pump, improves the vacuum adsorption speed, and shortens the forming cycle; optimizes the mold design, improves the heat transfer efficiency, and reduces the cooling or heating time; adopts a rapid-cycle water cooling system, reduces the cooling water temperature, and improves the cooling speed, and solves the problems of high energy consumption, long forming cycle, and low production efficiency in the prior art. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor. Among them:

[0019] Figure 1 The present invention provides an overall process flow chart of the energy-saving rapid cycle blister box vacuum forming process. Figure 2 The present invention is a flow chart of a method for pre-treating a mold surface. DETAILED DESCRIPTION

[0020] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0021] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0022] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0023] The existing vacuum forming process generally has the problems of high energy consumption, long forming cycle, low production efficiency, etc. Therefore, developing an energy-saving fast-cycle blister box vacuum forming process to solve the above problems has high practical value.

[0024] Specifically, participate in the following embodiments:

[0025] Embodiment 1:

[0026] See also Figure 1 The present invention provides an energy-saving fast-cycle blister box vacuum forming process, which is prepared by the following steps:

[0027] S1: placing the plastic sheet on a heating device for preheating, and the preheating temperature is controlled within a range of 5 to 10°C lower than the melting point of the plastic;

[0028] S2: placing the preheated plastic sheet on the mold, starting the vacuum pump to extract the air in the mold, so that the plastic sheet is adsorbed on the mold;

[0029] S3: Cool or heat the mold so that the plastic sheet reaches the predetermined molding temperature in a short time, and then apply pressure to make the plastic sheet fit tightly in the mold to form the desired product shape;

[0030] S4: Take the molded product out of the mold.

[0031] Furthermore, in step S1, when the plastic sheet is placed on the heating device for preheating, the heating time is determined according to the thickness of the plastic sheet and the preheating temperature, which is specifically achieved by the following formula:

[0032]

[0033] Where t is the heating time, s; k is the proportional constant, which is determined according to the specific characteristics of the plastic material. For polyethylene plastic, k is defined as 0.864; h is the thickness of the plastic sheet, mm; T preheat is the preheating temperature, °C; T room is room temperature, ℃; T melting is the melting point of the plastic, ℃.

[0034] Specifically, in step S3, the pressure applied is 100-120N.

[0035] Furthermore, before the preheated plastic sheet is placed in the mold, the molding mold needs to be cleaned to ensure the cleanliness of the mold surface;

[0036] Among them, the cleaning process first adopts wet cleaning and then adopts dry cleaning;

[0037] Among them, wet cleaning uses ethanol solvent;

[0038] Among them, dry cleaning uses blowing and vacuum cleaning.

[0039] Furthermore, participation Figure 2 , placing the preheated plastic sheet in front of the mold, and also including pre-treating the mold surface;

[0040] The preprocessing steps are as follows:

[0041] Step 1: Apply Fe3O4 coating to the mold surface;

[0042] Step 2: Let it stand for more than 30 minutes, until the Fe3O4 coating is firmly bonded to the mold surface, and then place the preheated plastic sheet in the molding mold.

[0043] Specifically, the coating thickness of the Fe3O4 coating is less than 1 mm.

[0044] Embodiment 2:

[0045] See also Figure 1 The present invention provides an energy-saving fast-cycle blister box vacuum forming process, which is prepared by the following steps:

[0046] S1: placing the plastic sheet on a heating device for preheating, and the preheating temperature is controlled within a range of 5 to 10°C lower than the melting point of the plastic;

[0047] S2: placing the preheated plastic sheet on the mold, starting the vacuum pump to extract the air in the mold, so that the plastic sheet is adsorbed on the mold;

[0048] S3: Cool or heat the mold so that the plastic sheet reaches the predetermined molding temperature in a short time, and then apply pressure to make the plastic sheet fit tightly in the mold to form the desired product shape;

[0049] S4: Take the molded product out of the mold.

[0050] Specifically, a segmented heating device is used, the preheating temperature is 80°C, and the preheating time is 2 minutes; a high-efficiency vacuum pump is used, and the vacuum adsorption time is 1 second; the mold design is optimized, and the cooling time is 10 seconds; a fast-circulating water cooling system is used, and the cooling water temperature is 15°C.

[0051] Specifically, in step S3, the pressure applied is 100-120N.

[0052] Furthermore, before the preheated plastic sheet is placed in the mold, the molding mold needs to be cleaned to ensure the cleanliness of the mold surface;

[0053] Among them, the cleaning process first adopts wet cleaning and then adopts dry cleaning;

[0054] Among them, wet cleaning uses ethanol solvent;

[0055] Among them, dry cleaning uses blowing and vacuum cleaning.

[0056] Furthermore, participation Figure 2, placing the preheated plastic sheet in front of the mold, and also including pre-treating the mold surface;

[0057] The preprocessing steps are as follows:

[0058] Step 1: Apply Fe3O4 coating to the mold surface;

[0059] Step 2: Let it stand for more than 30 minutes, until the Fe3O4 coating is firmly bonded to the mold surface, and then place the preheated plastic sheet in the molding mold.

[0060] Specifically, the coating thickness of the Fe3O4 coating is less than 1 mm.

[0061] Embodiment 3:

[0062] See also Figure 1 The present invention provides an energy-saving fast-cycle blister box vacuum forming process, which is prepared by the following steps:

[0063] S1: placing the plastic sheet on a heating device for preheating, and the preheating temperature is controlled within a range of 5 to 10°C lower than the melting point of the plastic;

[0064] S2: placing the preheated plastic sheet on the mold, starting the vacuum pump to extract the air in the mold, so that the plastic sheet is adsorbed on the mold;

[0065] S3: Cool or heat the mold so that the plastic sheet reaches the predetermined molding temperature in a short time, and then apply pressure to make the plastic sheet fit tightly in the mold to form the desired product shape;

[0066] S4: Take the molded product out of the mold.

[0067] Specifically, a segmented heating device is used, the preheating temperature is 85°C, and the preheating time is 3 minutes; a high-efficiency vacuum pump is used, and the vacuum adsorption time is 1.5 seconds; the mold design is optimized, and the cooling time is 12 seconds; a fast-circulating water cooling system is used, and the cooling water temperature is 18°C.

[0068] Specifically, in step S3, the pressure applied is 100-120N.

[0069] Furthermore, before the preheated plastic sheet is placed in the mold, the molding mold needs to be cleaned to ensure the cleanliness of the mold surface;

[0070] Among them, the cleaning process first adopts wet cleaning and then adopts dry cleaning;

[0071] Among them, wet cleaning uses ethanol solvent;

[0072] Among them, dry cleaning uses blowing and vacuum cleaning.

[0073] Furthermore, participation Figure 2 , placing the preheated plastic sheet in front of the mold, and also including pre-treating the mold surface;

[0074] The preprocessing steps are as follows:

[0075] Step 1: Apply Fe3O4 coating to the mold surface;

[0076] Step 2: Let it stand for more than 30 minutes, until the Fe3O4 coating is firmly bonded to the mold surface, and then place the preheated plastic sheet in the molding mold.

[0077] Specifically, the coating thickness of the Fe3O4 coating is less than 1 mm.

[0078] In order to verify that the energy-saving fast-cycle blister box vacuum forming process described in the present invention has the above-mentioned beneficial effects, the following simulation experiment is now carried out:

[0079] Purpose

[0080] The actual effect of the process of the present invention in reducing energy consumption, shortening the molding cycle and improving production efficiency was verified.

[0081] Experimental Materials

[0082] Plastic sheets of the same specifications (same thickness and material)

[0083] Conventional vacuum forming process equipment

[0084] Energy-saving rapid cycle blister box vacuum forming process equipment according to the present invention

[0085] Experimental equipment

[0086] Sectional heating device

[0087] High efficiency vacuum pump

[0088] Optimized mold design

[0089] Rapid circulation water cooling system

[0090] Experimental parameters

[0091] Preheating temperature

[0092] Warm-up time

[0093] Vacuum adsorption time

[0094] Cooling time

[0095] Cooling water temperature

[0096] Experimental procedures

[0097] Control group experiment: Use conventional vacuum forming process equipment to conduct experiments and record various parameters and energy consumption data.

[0098] Experimental group experiment: The process equipment of the present invention was used to conduct the experiment, and the following steps were followed:

[0099] S1: Place the plastic sheet on a segmented heating device for preheating. The preheating temperature is controlled within a range of 5 to 10°C lower than the melting point of the plastic. Record the preheating time.

[0100] S2: Place the preheated plastic sheet on the optimized mold, start the high-efficiency vacuum pump, and record the vacuum adsorption time.

[0101] S3: Maintain the vacuum state in the mold, allow the plastic sheet to form, and record the molding cycle.

[0102] S4: Use a fast-circulating water cooling system for cooling, and record the cooling time and cooling water temperature.

[0103] S5: Take the molded product out of the mold.

[0104] Data recording and analysis

[0105]

[0106] Data analysis

[0107] Energy consumption: The energy consumption of the experimental group was lower than that of the control group, indicating that the process of the present invention has energy-saving effect.

[0108] Molding cycle: The molding cycle of the experimental group was shorter than that of the control group, indicating that the process of the present invention can significantly shorten the molding time.

[0109] Production efficiency: The cooling time of the experimental group was shorter and the vacuum adsorption time was faster, which improved the production efficiency overall.

[0110] The above data prove that the solution described in the present invention has the beneficial effects of reducing energy consumption, shortening molding cycle and improving production efficiency.

[0111] The invention provides an energy-saving rapid-cycle blister box vacuum forming process, which adopts a segmented heating device to adjust the heating power according to the thickness of the plastic sheet and the preheating temperature, thereby reducing energy consumption; uses a high-efficiency vacuum pump to increase the vacuum adsorption speed and shorten the forming cycle; optimizes the mold design to increase the heat transfer efficiency and reduce the cooling or heating time; adopts a rapid-cycle water cooling system to reduce the cooling water temperature and increase the cooling speed, thereby solving the problems of high energy consumption, long forming cycle and low production efficiency in the prior art.

[0112] Importantly, it should be noted that the construction and arrangement of the present application shown in a plurality of different exemplary embodiments are only exemplary. Although only a few embodiments are described in detail in this disclosure, it should be readily understood by those who refer to this disclosure that many modifications are possible (e.g., the size, scale, structure, shape and proportion of various elements, and parameter values ​​(e.g., temperature, pressure, etc.), installation arrangement, use of materials, color, directional changes, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in the application. For example, the element shown as integrally formed can be composed of multiple parts or elements, the position of the element can be inverted or otherwise changed, and the nature or number or position of the discrete element can be changed or changed. Therefore, all such modifications are intended to be included in the scope of the present invention. The order or sequence of any process or method steps can be changed or reordered according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure of performing the function described herein, and is not only structurally equivalent but also equivalent structure. Without departing from the scope of the present invention, other replacements, modifications, changes and omissions can be made in the design, operating conditions and arrangement of the exemplary embodiments. Therefore, the invention is not limited to a specific embodiment, but extends to numerous modifications still falling within the scope of the appended claims.

[0113] Additionally, in order to provide a concise description of exemplary embodiments, all features of an actual embodiment (ie, those features that are not relevant to the best mode presently contemplated for carrying out the invention or those that are not relevant to implementing the invention) may not be described.

[0114] It will be appreciated that in the development of any actual implementation, as in any engineering or design project, numerous implementation-specific decisions may be made. Such a development effort may be complex and time-consuming, but will be a routine task of design, fabrication, and production for those of ordinary skill having the benefit of this disclosure without undue experimentation.

[0115] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should be included in the scope of the claims of the invention.

Claims

1. An energy-saving rapid cycle blister box vacuum forming process, characterized in that: Prepare by the following steps: S1: placing the plastic sheet on a heating device for preheating, and the preheating temperature is controlled within a range of 5 to 10°C lower than the melting point of the plastic; S2: placing the preheated plastic sheet on the mold, starting the vacuum pump to extract the air in the mold, and allowing the plastic sheet to be adsorbed on the mold; S3: Cool or heat the mold so that the plastic sheet reaches the predetermined molding temperature in a short time, and then apply pressure to make the plastic sheet fit tightly in the mold to form the desired product shape; S4: Take the molded product out of the mold.

2. The energy-saving fast-cycle blister box vacuum forming process according to claim 1, characterized in that: A segmented heating device is used, with a preheating temperature of 80°C and a preheating time of 2 minutes; a high-efficiency vacuum pump is used, with a vacuum adsorption time of 1 second; the mold design is optimized, with a cooling time of 10 seconds; a fast-circulating water cooling system is used, with a cooling water temperature of 15°C.

3. The energy-saving fast-cycle blister box vacuum forming process according to claim 1 is characterized in that: A segmented heating device is used, with a preheating temperature of 85°C and a preheating time of 3 minutes. A high-efficiency vacuum pump is used, with a vacuum adsorption time of 1.5 seconds. The mold design is optimized, with a cooling time of 12 seconds. A fast-circulating water cooling system is used, with a cooling water temperature of 18°C.

4. The energy-saving fast-cycle blister box vacuum forming process according to claim 1, characterized in that: In step S1, when the plastic sheet is placed on the heating device for preheating, the heating time is determined according to the thickness of the plastic sheet and the preheating temperature, which is specifically achieved by the following formula: Where t is the heating time, s; k is the proportional constant, which is determined according to the specific characteristics of the plastic material. For polyethylene plastic, k is defined as 0.864; h is the thickness of the plastic sheet, mm; T preheat is the preheating temperature, °C; T room is room temperature, ℃; T melting is the melting point of the plastic, ℃.

5. The energy-saving fast-cycle blister box vacuum forming process according to any one of claims 1 or 4, characterized in that: In step S3, the applied pressure is 100-120N.

6. The energy-saving fast-cycle blister box vacuum forming process according to claim 5, characterized in that: The preheated plastic sheet is placed in front of the mold, and the molding mold needs to be cleaned to ensure the cleanliness of the mold surface; Among them, the cleaning process first adopts wet cleaning and then adopts dry cleaning; Among them, wet cleaning uses ethanol solvent; Among them, dry cleaning uses blowing and vacuum cleaning.

7. The energy-saving fast-cycle blister box vacuum forming process according to claim 6, characterized in that: Placing the preheated plastic sheet in front of the mold, and also pre-treating the mold surface; The preprocessing steps are as follows: Step 1: Apply Fe3O4 coating to the mold surface; Step 2: Let it stand for more than 30 minutes, until the Fe3O4 coating is firmly bonded to the mold surface, and then place the preheated plastic sheet in the molding mold.

8. The energy-saving fast-cycle blister box vacuum forming process according to claim 7, characterized in that: The coating thickness of Fe3O4 coating is less than 1mm.

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