Lightweight double-section blowing type forming process for glass bottle

Abstract

The invention provides a light-weight double-section blowing type forming process for a glass bottle, belongs to the field of glass product processing, and solves the problems of low forming production efficiency, insufficient precision, poor system performance and the like of the existing glass bottle. Comprising the following steps: S1, preparing and melting raw materials; s2, feeding and prototype forming; s3, shaping and strengthening; s4, annealing treatment; and S5, carrying out online detection and sorting. According to the invention, through double-section pressure blowing and addition of a special reinforcing agent, the difficult problem of consideration of light weight and strength is successfully solved, dynamic initial blowing pressure control based on viscosity and servo precise control of mold movement are adopted, and an online laser thickness measurement and intelligent feedback system is combined, so that process parameters can be automatically and finely adjusted, and the consistency and qualified rate of products are improved; each core module is provided with an electric three-dimensional positioning mechanism, so that quick and accurate centering and cooperative adjustment of the mold are realized; a whole-process quality monitoring system from forming to delivery is integrated, the mechanical reliability and durability of each delivery product are ensured, and defective products are avoided.

Description

Technical Field

[0001] This invention belongs to the field of glass product processing technology, and relates to a glass bottle forming process, particularly a lightweight two-stage blow molding process for glass bottles. Background Technology

[0002] With increasingly stringent environmental policies and the need to control packaging costs, lightweight glass bottles have become an inevitable trend in the liquor packaging industry. However, traditional glass bottle manufacturing processes face three major technological bottlenecks in achieving lightweighting: 1. The contradiction between strength and lightweight: When the bottle wall thickness is reduced to below 2.0mm, the internal pressure resistance and impact resistance of the glass bottle decrease significantly. For example, in a drop test from a height of 1.5 meters, the breakage rate can exceed 15%, failing to meet transportation and usage requirements.

[0003] 2. Insufficient molding precision: Traditional single-stage blow molding processes lack precise parameter control, resulting in poor uniformity of bottle wall thickness, with errors reaching ±0.3mm. Uneven wall thickness easily leads to stress concentration, causing the finished product qualification rate of lightweight glass bottles to be only about 75%.

[0004] 3. Outdated testing technology: Traditional ultrasonic thickness measurement technology has an accuracy of only ±0.1mm, which cannot meet the high-precision testing requirements of lightweight thin-walled bottles (tolerance needs to be controlled within ±0.05mm). Quality control relies on manual experience and has poor stability.

[0005] Based on this, we propose a lightweight two-stage blow molding process for glass bottles. Summary of the Invention

[0006] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a lightweight two-stage blow molding process for glass bottles. The technical problem this invention aims to solve is: how to achieve significant lightweighting while ensuring the glass bottle possesses excellent structural strength, and improve product qualification rate, production efficiency, and intelligent level, through innovative bottle structure design, precise two-stage blow molding control, intelligent online feedback system, and dedicated high-strength glass materials.

[0007] The objective of this invention can be achieved through the following technical solutions: A lightweight two-stage blow molding process for glass bottles includes the following steps: S1. Raw material preparation and melting: Mix 48-58% quartz sand, 12-16% soda ash, 4-7% limestone and crushed glass by weight percentage, wherein the proportion of crushed glass is 25-35%. At the same time, add 1-3% ZrO2 as a reinforcing agent and 0.5-1.5% Li2O as a flux. Heat the mixture in a tank furnace to 1500-1550℃ to melt it into a uniform glass melt. S2. Feeding and Preliminary Forming: The molten glass obtained in step S1 is cooled to a suitable forming temperature of 1150-1250℃. It is then sheared into droplets of a specific weight by a feeder and falls into the preliminary mold cavity formed by the internal spaces of the preliminary gas injection top mold assembly, the preliminary mold assembly, and the flipping transfer mold assembly. Gas is injected into the interior of the preliminary mold assembly through the preliminary gas injection top mold assembly, squeezing the molten glass droplets downwards to make them stably fill the cavity. The preliminary gas injection bottom mold assembly performs the first stage of gas injection and blowing from bottom to top: The initial blowing pressure P1 is dynamically adjusted according to the real-time viscosity μ of the molten glass, satisfying the relationship: P1=kln(μ)+b, where k and b are coefficients determined by simulation optimization based on the bottle shape. P1 is maintained in a low pressure range of 0.28-0.32MPa for initial blowing to form the preliminary preform. S3. Shaping and Strengthening: The transfer mold assembly transfers the preform formed in the initial mold assembly to the forming mold assembly. The forming gas injection top mold assembly performs the second stage of gas injection and blowing from top to bottom: the final blowing is performed at a higher pressure of 0.48-0.52MPa, so that the glass preform is tightly attached to the forming mold assembly, and the bottle body is accurately formed. During this process, the opening and closing speed of the mold is precisely controlled by a servo motor. S4. Annealing: The clamping and transferring assembly transfers the formed glass bottle to the conveyor chain and feeds it into the annealing furnace. The annealing furnace adopts a low-temperature annealing process, sets a specific annealing temperature curve, and reduces the cooling rate by 15-25% compared with the traditional process to eliminate internal stress. S5. Online inspection and sorting: After annealing, the glass bottles enter the inspection station. First, a laser thickness gauge is used to scan the bottle body from all directions, and products with unqualified wall thickness uniformity are rejected. Intelligent feedback control: When the system detects that the wall thickness of a specific area of ​​the bottle exceeds the tolerance range multiple times in a row, the central controller automatically fine-tunes the pressure parameters of the corresponding side blowing head or the closing gap of the mold to achieve closed-loop adaptive adjustment of process parameters. Subsequently, multi-angle drop tests and internal pressure resistance tests were conducted to ensure the mechanical strength of the product.

[0008] When the system detects that the wall thickness of a specific area of ​​the bottle exceeds the tolerance range multiple times in a row, the central controller can automatically provide feedback and fine-tune the pressure parameters of the corresponding side blowing head or the closing gap of the mold.

[0009] The laser thickness gauge has a measurement accuracy of ±0.02mm, a drop test height of 1.2m-1.5m, and an internal pressure test pressure of not less than 60kPa.

[0010] The equipment used in steps S2 and S3 includes, from left to right, a preliminary mold frame, a material transfer mold assembly, a forming venting bottom mold, and a forming mold frame. The preliminary mold frame has, from bottom to top, a preliminary venting bottom mold assembly, a preliminary mold assembly, a material injection mold assembly, and a preliminary venting top mold assembly. The forming mold frame has, from bottom to top, a forming mold assembly and a forming venting top mold assembly. The forming mold assembly is located above the forming venting bottom mold. The forming mold frame also has a clamping and transferring assembly located directly in front of the forming venting top mold assembly. The preliminary venting bottom mold assembly, the preliminary venting top mold assembly, the forming venting top mold assembly, and the forming venting bottom mold are all connected to an external air pump via solenoid valves.

[0011] With the above structure, the forming mold assembly abuts against the top of the forming venting bottom mold, the flipping and transferring mold assembly abuts against the top of the initial venting bottom mold assembly, the initial mold assembly abuts against the top of the flipping and transferring mold assembly, and the injection mold assembly abuts against the top of the initial mold assembly, so that the glass liquid material cooled to a suitable temperature is dripped into the initial mold assembly; The initial gas injection top mold assembly moves to contact the top of the injection mold assembly. Through the cooperation of the air pump and solenoid valve, air is injected into the interior of the initial mold assembly via the initial gas injection top mold assembly, squeezing the glass liquid droplet downwards, so that the glass liquid droplet steadily and completely fills the top of the transfer mold assembly and the interior of the initial mold assembly. The initial gas injection ejector assembly is raised, the injection mold assembly is moved out, and then the initial gas injection ejector assembly is moved to abut against the top of the initial mold assembly. At this time, the air hole of the initial gas injection ejector assembly is blocked by the initial mold assembly, and the initial gas injection ejector assembly blocks the upper opening of the initial mold assembly. The internal space of the initial gas injection ejector assembly, the initial mold assembly and the flipping transfer mold assembly forms the initial mold cavity. By using an air pump and a solenoid valve, air is injected into the cavity of the initial mold through the initial air injection bottom mold assembly, forming a primary blank with uniform wall thickness inside the cavity. Then the initial gas injection mold assembly, the initial mold assembly, and the injection mold assembly are removed. The flipping and transfer mold assembly is rotated 180 degrees in the opposite direction, which drives the initial blank to be transferred into the forming mold assembly. Then the flipping and transfer mold assembly is rotated 180 degrees in the forward direction and reset. The forming gas injection top mold assembly moves to contact the top of the forming mold assembly, injecting gas into the forming mold assembly. High pressure is used in this stage to make the glass preform completely fit into the inside of the forming mold assembly, achieving a precise shape. The molding and venting top mold assembly moves, retracts, and resets; the clamping and transferring assembly clamps the glass preform; the molding mold assembly opens and leaves the molding and venting bottom mold; and the clamping and transferring assembly transfers the glass preform to the conveyor chain.

[0012] The initial air-injection bottom mold assembly includes an electrically adjustable bottom mold base that can be moved and adjusted on the initial mold frame. A bottom mold mounting rod is fixed on the electrically adjustable bottom mold base. Several bottom mold fixing seats are provided on the bottom mold mounting rod. An adjustable bottom mold lifting air injection rod is provided inside the bottom mold fixing seat. The bottom mold lifting air injection rod is connected to an external air pump through a solenoid valve.

[0013] With the above structure, the bottom mold electric adjustment seat can be moved and adjusted on the initial mold frame. The movement and adjustment include, but are not limited to, lifting, moving forward, backward, left and right. Through electric adjustment, the position of the initial gas injection bottom mold assembly in three-dimensional space can be precisely controlled; ensuring that the bottom mold lifting gas injection rod on it can be accurately aligned with the bottom center of the initial mold assembly, which meets the needs of mold replacement or production centering debugging for different bottle types.

[0014] The bottom mold lifting air injection rod is installed inside the bottom mold fixing base and can be adjusted for lifting. Lifting function: During the working cycle, the bottom mold lifting air injection rod can be raised so that its top end is in close contact with the bottom of the flipping transfer mold assembly above, forming a seal and creating a closed air cavity (i.e., the initial mold cavity) for air blowing.

[0015] Air injection function: In the sealed position, through its internal channel, it connects to an external air pump and solenoid valve to precisely and stably inject compressed air into the glass droplet in the primary mold cavity, completing the first stage of blowing (initial blowing).

[0016] Reset and avoidance: After the air blowing is completed, the bottom mold lifting air injection rod descends and disengages from the flipping and transferring mold assembly, making room for subsequent mold opening and blank transfer operations.

[0017] The initial mold assembly includes an electrically adjustable initial mold base that can be moved and adjusted on the initial mold frame. An initial mold mounting rod is fixed on the electrically adjustable initial mold base. Several initial mold bodies are provided on the initial mold mounting rod, and the initial mold bodies are located above the bottom mold fixing base at the corresponding positions.

[0018] With the above structure, the electric adjustment seat of the initial mold can be moved and adjusted on the initial mold frame. The movement and adjustment include, but are not limited to, lifting, moving forward, backward, left and right. Through electric adjustment, the position of the initial mold component in three-dimensional space can be precisely controlled. Precise alignment: This ensures that the primary mold body can be accurately positioned and tightly pressed against the flipping and transferring mold assembly below, forming a seal.

[0019] Precise alignment: This ensures that the opening above the main body of the primary mold can accurately align with and be sealed by the primary air injection top mold assembly.

[0020] Quick changeover: When producing bottle shapes of different specifications, the position of the entire initial mold assembly can be quickly adjusted by electric adjustment to adapt to the new mold size, ensuring precise matching with other components in the system, greatly improving production flexibility and efficiency.

[0021] The main body of the primary mold contains a pre-set primary blank cavity. When it is driven to the working position by the electric adjustment seat of the primary mold and closed with the upper and lower primary air injection mold assembly and the flipping transfer mold assembly, it together forms a closed primary mold cavity. The primary mold cavity is the space in which the glass droplet is formed into the primary blank in the first stage of blowing.

[0022] The injection mold assembly includes an electric injection mold adjusting seat that can be moved and adjusted on the primary mold frame. An injection mold mounting rod is fixed on the electric injection mold adjusting seat. Several injection mold bodies are provided on the injection mold mounting rod, and the injection mold bodies are located above the primary mold bodies at corresponding positions.

[0023] With the above structure, the electric adjustment seat of the injection mold can be moved and adjusted on the initial mold frame. The movement and adjustment include, but are not limited to, lifting, moving forward, backward, left and right. Through electric adjustment, the position of the injection mold assembly in three-dimensional space can be precisely controlled. Precise alignment: This ensures that the outlet below the injection mold body is precisely aligned and tightly pressed against the inlet above the primary mold body, forming a continuous glass liquid flow channel and preventing droplets from splashing or adhering to the joints.

[0024] Collaborative changeover: When changing bottle type and simultaneously adjusting the position of the initial mold assembly, the injection mold assembly can be adjusted in conjunction with its injection mold electric adjustment seat to always maintain precise alignment with the initial mold. This ensures that molds of different sizes can obtain accurate injection, which is the key to achieving rapid production changeover and improving production line flexibility.

[0025] The injection mold body has a cavity inside, which acts like a funnel to receive high-temperature glass droplets of a specific weight falling from the feeder and guide them into the primary mold body directly below.

[0026] The initial gas injection mold assembly includes an electrically adjustable initial mold base that can be moved and adjusted on the initial mold frame. An initial mold mounting rod is fixed on the electrically adjustable initial mold base. An initial mold mounting rod is provided with an injection connector and several initial gas injection mold heads. The initial gas injection mold heads are located above the corresponding positions of the initial mold body. The lower end of the injection connector is connected to the initial gas injection mold head through a pipe. The upper end of the injection connector is connected to an external air pump through a solenoid valve.

[0027] With the above structure, the electric adjustment seat of the primary mold top mold can be moved and adjusted on the primary mold frame. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the primary air injection top mold assembly in three-dimensional space can be precisely controlled. Injection Position: Precise movement allows the initial gas injection ejector head to move to and seal the upper end of the injection mold assembly. Gas is then injected into the initial mold body through the gas injection connector and internal pipes. The air pressure forces the newly fallen glass droplet downwards, ensuring it is stably, fully, and evenly distributed on the bottom of the initial mold and the transfer mold assembly, forming an ideal blank base for subsequent blowing. This adjustment function also facilitates rapid mold changeovers, allowing for synchronous adjustment with other components in the system to ensure precision.

[0028] Sealing position: After the injection mold assembly is removed, it can move precisely again. The initial injection ejector head moves to and seals the upper opening of the initial mold assembly, forming a seal. At this time, its air holes are blocked by the mold structure, and it no longer blows air directly. At this time, the initial injection ejector head forms a sealing cover, which together with the initial mold assembly below and the flipping transfer mold assembly constitutes a completely closed initial mold cavity. The initial mold cavity is a necessary prerequisite for the subsequent low-pressure air blowing by the initial injection bottom mold assembly to form a preliminary blank with uniform wall thickness.

[0029] The flipping and transferring mold assembly includes an electric flipping base. A flipping mounting rod and a limiter are fixedly mounted on the flipping shaft of the electric flipping base. Several transferring mold bodies are mounted on the flipping mounting rod. In the initial position, the transferring mold body is located above the bottom mold fixing base at the corresponding position. After the electric flipping base is flipped 180 degrees, the transferring mold body is located between the molding gas injection top mold assembly and the molding mold assembly.

[0030] With the above structure, the initial position is as follows: In the initial molding stage, the transfer mold body is located between the initial gas injection bottom mold assembly directly below it and the initial mold assembly directly above it. At this time, it is in close contact with the upper and lower molds, and together they form the bottom of the initial mold cavity. Its inner cavity shape directly participates in forming the bottom outline of the initial blank and reliably receives the glass droplets and blowing pressure from above.

[0031] The electric tilting seat's tilting shaft drives all the material transfer mold bodies to move synchronously via the tilting mounting rod.

[0032] Clamping and release: After the initial mold is blown and the surrounding molds are opened, the main body of the transfer mold is usually equipped with a clamping mechanism that can firmly hold the initial mold blank.

[0033] The electric tilting seat drives the transfer mold body to rotate 180 degrees in the opposite direction, accurately transporting the preform from the preform mold holder station to the forming mold holder station, and positioning it between the forming mold assembly and the forming gas injection ejector assembly. The preform is then moved to the forming mold assembly, where it is clamped. The transfer mold body releases the preform, and the electric tilting seat rotates 180 degrees in the forward direction, causing the empty transfer mold body to return to its initial position, ready to receive the next preform and begin a new work cycle.

[0034] The molding gas injection top mold assembly includes a molding top mold electric adjustment seat that can be moved and adjusted on the molding mold frame. A molding top mold mounting rod is fixed on the molding top mold electric adjustment seat. Several molding gas injection top mold heads are provided on the molding top mold mounting rod. Each molding gas injection top mold head is provided with a lifting and adjusting top mold lifting gas injection rod. The molding top mold electric adjustment seat is provided with a second gas injection connector. The lower end of the second gas injection connector is connected to several top mold lifting gas injection rods through a pipe. The upper end of the second gas injection connector is connected to an external air pump through a solenoid valve.

[0035] With the above structure, the electric adjustment seat of the molding top mold can be moved and adjusted on the molding mold frame. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the molding gas injection top mold assembly in three-dimensional space can be precisely controlled. Ensures that the molding injection ejector head can move precisely and abut against the upper opening of the molding die assembly; this adjustment function also serves quick changeovers, allowing for synchronous adjustment with other components when changing bottle types to ensure precise fit of the sealing surfaces.

[0036] When the molding gas injection top mold assembly moves to the working position, its molding gas injection top mold head forms a seal with the upper end of the molding mold assembly. At the same time, the top mold lifting gas injection rod inside descends, passes through and extends out of the top mold head, and directly inserts into and seals the bottle mouth of the preform transferred from the flipping material transfer mold assembly.

[0037] Establishing a high-pressure gas path: The downward movement of the top mold lifting air injection rod forms a unique and sealed high-pressure air intake channel with the bottle mouth of the billet. The high-pressure gas is collected through the second air injection joint and the internal pipe to each top mold lifting air injection rod, and then precisely and stably injected directly into the interior of the billet.

[0038] Final blow shaping: The pressure injected in this stage is much higher than that in the initial blow stage; the high pressure forces the heated and softened glass preform to expand fully in all directions until it is completely attached to the inner wall of the forming mold assembly, thereby replicating the precise inner cavity shape of the mold and completing the final shaping of the bottle body and the shaping of surface details.

[0039] Reset and avoidance (cycle preparation): After the final blowing is completed, the top mold lifting and air injection rod first rises and disengages from the bottle mouth of the preform. The entire molding air injection top mold assembly moves, retracts, and resets; this makes room for the subsequent clamping and material transfer assembly to enter and remove the formed glass bottle.

[0040] The clamping and transferring assembly includes a movable and adjustable electric adjustment seat on the forming mold frame, an electric rotating seat on the electric adjustment seat, and a plurality of electric grippers on the electric rotating seat.

[0041] Using the above structure, the electric transfer adjustment seat can be moved and adjusted on the forming mold frame. The movement and adjustment include, but are not limited to, lifting, moving forward, backward, left and right. Through electric adjustment, the position of the clamping and transferring component in three-dimensional space can be precisely controlled. After the molding and injection mold assembly is reset and the molding mold assembly is opened, the electric adjustment seat drives the entire assembly to move, so that the electric gripper is precisely positioned and enters the mold above the already shaped glass bottle.

[0042] The electric gripper performs the gripping action, firmly and stably grasping the neck or body of the glass bottle, preparing it for transfer.

[0043] After clamping the glass bottle, the electric rotary seat drives the entire clamping mechanism to rotate at a specific angle, quickly transporting the glass bottle from the molding station located on the molding mold frame to the top of the adjacent conveyor chain.

[0044] Once the glass reaches the designated position, the electric gripper releases, smoothly releasing the finished glass bottle onto the conveyor chain for subsequent annealing or testing processes.

[0045] After the bottle is released, the electric rotary seat rotates in the opposite direction, and at the same time, the electric adjustment seat moves in coordination, driving the empty electric gripper back to the standby position above the molding die, ready to execute the next work cycle.

[0046] The molding die assembly includes an electrically adjustable molding die base that can be moved and adjusted on the molding die frame. A molding die mounting rod is fixed on the electrically adjustable molding die base. Several molding die bodies are provided on the molding die mounting rod. The molding die bodies are located above the molding venting bottom die at the corresponding position. The interior of the molding die body is provided with distributed cooling channels, through which a constant temperature cooling medium is introduced to maintain the surface temperature of the mold cavity at 200-300℃, with a fluctuation range of ±5℃, to ensure thermal stability during the molding process.

[0047] With the above structure, the electric adjustment seat of the molding mold can be moved and adjusted on the molding mold frame. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the molding mold assembly in three-dimensional space can be precisely controlled. Electric adjustment allows for precise control of the entire molding assembly's position within space, achieving two key seals: Precise alignment: This ensures that the main body of the molding mold can be accurately positioned and tightly pressed against the bottom molding and venting mold below, forming a sealed bottom of the mold.

[0048] Precise closure: Ensures that the molding body of the left and right or front and back molds can be perfectly aligned to form a complete and seamless bottle cavity.

[0049] Quick changeover: When producing different bottle types, the position of the entire mold set can be quickly adjusted by electric adjustment to adapt to the size of the new mold and maintain precise fit with the molding injection top mold assembly and the molding venting bottom mold, greatly improving the flexibility of the production line.

[0050] Final blow molding and venting: The molding die mounting rod and the molding die body are the core functional parts of the component.

[0051] The molding die mounting rod provides robust structural support, ensuring that all molding die bodies open and close synchronously and stably.

[0052] The inner cavity of the molding mold body is engraved with the final, precise outline of the glass bottle; when it is closed with the molding venting bottom mold, it forms the final blow molding cavity.

[0053] During the final blowing stage, high-pressure gas forces the glass preform to adhere tightly to the inner wall of the mold cavity, completing the final shaping. In this process, the forming and venting bottom mold may be equipped with tiny venting channels to expel air from the mold cavity, ensuring that the bottle surface is free of defects and can be completely fitted.

[0054] Mold opening and transfer: After the final blow molding is completed, the electric adjustment seat of the molding mold drives the main body of the molding mold to open, detaching from the formed glass bottle and the molding venting bottom mold, making room for the clamping and transfer components to enter and remove the product.

[0055] The primary mold body and the final mold body are made of H13 hot work die steel, and their cavity surfaces are coated with a diamond-like coating with a thickness of 2-4μm, wherein the atomic percentage of tungsten is 5-10%, and the coefficient of friction of the coating surface is less than 0.15.

[0056] A lightweight glass bottle manufactured by the above molding process, wherein the bottom of the glass bottle is a dish-shaped structure with annular reinforcing ribs, and the ratio of the radius R of the cross-section of the annular reinforcing ribs to the diameter D of the bottle body satisfies: R / D=0.08-0.12.

[0057] The glass bottle has a gradually changing wall thickness from the bottle body to the neck. The bottle body wall thickness is 1.8-2.0 mm, gradually thinning to 1.2-1.4 mm towards the neck. The axial length L of the gradually changing wall thickness zone is 1.5-2.5 times the neck diameter d.

[0058] Compared with existing technologies, this lightweight two-stage blow molding process for glass bottles has the following advantages: This process, through two-stage pressure blowing and the addition of special reinforcing agents, reduces the weight of glass bottles while improving impact resistance by utilizing an optimized dish-shaped bottle bottom and annular reinforcing rib structure, thus solving the problem of balancing lightweight and strength.

[0059] This process employs viscosity-based dynamic initial blowing pressure control and servo precision control of mold movement, combined with online laser thickness measurement and intelligent feedback system, which can automatically fine-tune process parameters to ensure uniform and accurate wall thickness, thereby improving product consistency and yield.

[0060] Each core module of this process is equipped with an electric three-dimensional adjustment mechanism, enabling rapid and precise mold alignment and coordinated adjustment. This reduces debugging time when changing bottle types, gives the production line a high degree of flexibility and adaptability, and meets the needs of multi-variety production.

[0061] This process integrates a complete quality monitoring system from molding to delivery, including high-precision wall thickness scanning, multi-angle drop testing, and internal pressure resistance testing, to ensure the mechanical reliability and durability of each product leaving the factory and to eliminate defective products.

[0062] This process employs low-temperature, slow-speed annealing, reducing energy consumption. The formulation incorporates up to 30% recycled glass, minimizing raw material consumption and waste. The lightweight design also directly reduces packaging and transportation costs, resulting in significant economic and environmental benefits. Attached Figure Description

[0063] Figure 1 This is a schematic diagram of the molding process of the present invention.

[0064] Figure 2 This is a schematic diagram of the structure of some molding equipment in the initial state of the present invention.

[0065] Figure 3 This is a schematic diagram of the structure of some molding equipment in this invention during material feeding.

[0066] Figure 4 This is a schematic diagram of the upper air injection pressure of some molding equipment in this invention.

[0067] Figure 5 This is a schematic diagram of the structure of some molding equipment in the present invention during the initial blow molding process.

[0068] Figure 6 This is a schematic diagram of the structure of some forming equipment in this invention during the flipping and transfer of the initial blank.

[0069] Figure 7 This is a schematic diagram of the structure of some molding equipment in this invention before the shaping and blowing process.

[0070] Figure 8 This is a schematic diagram of the structure of some molding equipment in this invention during the shaping and blowing process.

[0071] Figure 9 This is a schematic diagram of the structure of some molding equipment in this invention after the shaping and blowing process.

[0072] Figure 10This is a schematic diagram of the structure of some of the forming equipment in this invention during the clamping and transfer of the formed glass bottle.

[0073] Figure 11 This is a performance comparison table of various cases in this invention.

[0074] In the diagram, 1. Primitive mold base; 2. Primitive injection bottom mold assembly; 3. Primitive mold assembly; 4. Injection mold assembly; 5. Primitive injection top mold assembly; 6. Flipping and transferring mold assembly; 7. Molding injection top mold assembly; 8. Clamping and transferring assembly; 9. Molding mold base; 10. Molding mold assembly; 11. Molding venting bottom mold; 12. Bottom mold mounting rod; 13. Bottom mold lifting and injection rod; 14. Bottom mold fixing seat; 15. Bottom mold electric adjustment seat; 16. Primitive mold body; 17. Primitive mold mounting rod; 18. Injection mold mounting rod; 19. Injection mold body; 20. Injection mold electric adjustment seat; 21. Primitive mold... 21. Electric mold adjustment seat; 22. Air injection connector one; 23. Initial mold top mold mounting rod; 24. Initial mold air injection top mold head; 25. Initial mold top mold electric adjustment seat; 26. Flip mounting rod; 27. Limiter; 28. Electric flip seat; 29. ​​Transfer mold body; 30. Air injection connector two; 31. Top mold lifting air injection rod; 32. Molding air injection top mold head; 33. Molding top mold electric adjustment seat; 34. Molding top mold mounting rod; 35. Electric gripper; 36. Transfer electric adjustment seat; 37. Electric rotating seat; 38. Molding mold body; 39. Molding mold mounting rod; 40. Molding mold electric adjustment seat. Detailed Implementation

[0075] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0076] like Figure 1 As shown, the lightweight two-stage blow molding process for this glass bottle includes the following steps: S1. Raw material preparation and melting: Mix 48-58% quartz sand, 12-16% soda ash, 4-7% limestone and crushed glass by weight percentage, wherein the proportion of crushed glass is 25-35%. At the same time, add 1-3% ZrO2 as a reinforcing agent and 0.5-1.5% Li2O as a flux. Heat the mixture in a tank furnace to 1500-1550℃ to melt it into a uniform glass melt. S2. Feeding and Preliminary Forming: The molten glass obtained in step S1 is cooled to a suitable forming temperature of 1150-1250℃. It is then sheared into droplets of a specific weight by a feeder and falls into the preliminary mold cavity formed by the internal spaces of the preliminary gas injection top mold assembly 5, the preliminary mold assembly 3, and the flipping transfer mold assembly 6. Gas is injected into the interior of the preliminary mold assembly 3 through the preliminary gas injection top mold assembly 5, squeezing the molten glass droplets downwards to make them stably fill the cavity. The preliminary gas injection bottom mold assembly 2 performs the first stage of gas injection and blowing from bottom to top: The initial blowing pressure P1 is dynamically adjusted according to the real-time viscosity μ of the molten glass, satisfying the relationship: P1=kln(μ)+b, where k and b are coefficients determined by simulation optimization based on the bottle shape. P1 is maintained in a low pressure range of 0.28-0.32MPa for initial blowing to form the preliminary preform. S3. Shaping and Strengthening: The transfer mold assembly 6 transfers the initial blank formed in the initial mold assembly 3 to the forming mold assembly 10. The forming gas injection top mold assembly 7 performs the second stage of gas injection blowing from top to bottom: the final blowing is performed at a higher pressure of 0.48-0.52MPa, so that the glass blank is tightly attached to the forming mold assembly 10, and the bottle body is accurately formed. During this process, the opening and closing speed of the mold is precisely controlled by a servo motor with an accuracy of ±1mm / s. S4. Annealing treatment: The clamping and transferring component 8 transfers the formed glass bottle to the conveyor chain and sends it into the annealing furnace. The annealing furnace adopts a low-temperature annealing process, sets a specific annealing temperature curve, and reduces the cooling rate by 15-25% compared with the traditional process to eliminate internal stress. S5. Online inspection and sorting: After annealing, the glass bottles enter the inspection station. First, a laser thickness gauge is used to scan the bottle body in all directions with a measurement accuracy of ±0.02mm. Products with unqualified wall thickness uniformity are rejected. Intelligent feedback control: When the system detects that the wall thickness of a specific area of ​​the bottle exceeds the tolerance range multiple times in a row, the central controller automatically fine-tunes the pressure parameters of the corresponding side blowing head or the closing gap of the mold to achieve closed-loop adaptive adjustment of process parameters. Subsequently, multi-angle drop tests (set height 1.2m-1.5m) and internal pressure resistance tests (pressure ≥60kPa) were conducted to ensure the mechanical strength of the product.

[0077] When the system detects that the wall thickness of a specific area of ​​the bottle exceeds the tolerance range multiple times in a row, the central controller can automatically provide feedback and fine-tune the pressure parameters of the corresponding side blowing head or the closing gap of the mold.

[0078] The laser thickness gauge has a measurement accuracy of ±0.02mm, a drop test height of 1.2m-1.5m, and an internal pressure test pressure of no less than 60kPa.

[0079] like Figures 2-10As shown, a lightweight two-stage blow molding process for glass bottles is described. The equipment used in steps S2 and S3 includes a preliminary mold frame 1, a material transfer mold assembly 6, a molding venting bottom mold 11, and a molding mold frame 9 arranged sequentially from left to right. The preliminary mold frame 1 is provided with a preliminary gas injection bottom mold assembly 2, a preliminary mold assembly 3, a material injection mold assembly 4, and a preliminary gas injection top mold assembly 5 arranged sequentially from bottom to top. The molding mold frame 9 is provided with a molding mold assembly 10 and a molding gas injection top mold assembly 7 arranged sequentially from bottom to top. The molding mold assembly 10 is located above the molding venting bottom mold 11. The molding mold frame 9 is also provided with a clamping and transferring assembly 8, which is located directly in front of the molding gas injection top mold assembly 7. The preliminary gas injection bottom mold assembly 2, the preliminary gas injection top mold assembly 5, the molding gas injection top mold assembly 7, and the molding venting bottom mold 11 are all connected to an external air pump via a solenoid valve.

[0080] The forming mold assembly 10 abuts against the forming venting bottom mold 11, the flipping and transferring mold assembly 6 abuts against the initial venting bottom mold assembly 2, the initial mold assembly 3 abuts against the flipping and transferring mold assembly 6, and the injection mold assembly 4 abuts against the initial mold assembly 3, and the glass liquid material cooled to a suitable temperature is dripped into the initial mold assembly 3. The initial gas injection ejector assembly 5 moves to contact the top of the injection mold assembly 4. Through the cooperation of an air pump and a solenoid valve, air is injected into the interior of the initial mold assembly 3 via the initial gas injection ejector assembly 5, squeezing downwards the molten glass droplets, such as... Figure 4 As shown, the glass molten material droplets are stably and downwardly filled, filling the area above the flipping and transferring mold assembly 6 and inside the initial mold assembly 3; The initial gas injection ejector assembly 5 is raised, the injection mold assembly 4 is moved out, and then the initial gas injection ejector assembly 5 is moved to abut against the top of the initial mold assembly 3. At this time, the air hole of the initial gas injection ejector assembly 5 is blocked by the initial mold assembly 3, and the initial gas injection ejector assembly 5 blocks the upper opening of the initial mold assembly 3. The internal space of the initial gas injection ejector assembly 5, the initial mold assembly 3 and the flipping transfer mold assembly 6 forms the initial mold cavity. Through the cooperation of an air pump and a solenoid valve, air is injected into the cavity of the primary mold cavity via the primary air injection bottom mold assembly 2, forming a primary blank with uniform wall thickness inside the cavity, such as... Figure 5 As shown; Then, the initial injection mold assembly 2, the initial mold assembly 3, and the injection mold assembly 4 are disassembled, and the transfer mold assembly 6 is rotated 180 degrees in the opposite direction, transferring the initial blank to the forming mold assembly 10. Figure 6 As shown, the transfer mold assembly 6 is then rotated 180 degrees in the forward direction and reset, as indicated. Figure 7 As shown; The molding and injection ejector assembly 7 moves to contact the top of the molding mold assembly 10, injecting air into the molding mold assembly 10, such as... Figure 8As shown, this stage uses higher pressure to completely conform the glass preform to the interior of the molding mold assembly 10, achieving a precise shape, such as... Figure 9 As shown; The molding and venting ejector assembly 7 moves, retracts, and resets; the clamping and transferring assembly 8 clamps the glass preform; the molding mold assembly 10 opens, separating from the molding and venting bottom mold 11; and the clamping and transferring assembly 8 transfers the glass preform to the conveyor chain. Figure 10 As shown.

[0081] The initial air-injection bottom mold assembly 2 includes an electric bottom mold adjusting seat 15 that can be moved and adjusted on the initial mold frame 1. A bottom mold mounting rod 12 is fixed on the bottom mold electric adjusting seat 15. Several bottom mold fixing seats 14 are provided on the bottom mold mounting rod 12. An adjustable bottom mold lifting air injection rod 13 is provided inside the bottom mold fixing seat 14. The bottom mold lifting air injection rod 13 is connected to an external air pump through a solenoid valve.

[0082] The bottom mold electric adjustment seat 15 can be moved and adjusted on the initial mold frame 1. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the initial gas injection bottom mold assembly 2 in three-dimensional space can be precisely controlled; ensuring that the bottom mold lifting gas injection rod 13 on it can be accurately aligned with the bottom center of the initial mold assembly 3, which meets the needs of mold replacement or production centering and debugging for different bottle types.

[0083] The bottom mold lifting air injection rod 13 is installed inside the bottom mold fixing seat 14 and can be adjusted for lifting. Lifting function: During the working cycle, the bottom mold lifting air injection rod 13 can be raised so that its top end is in close contact with the bottom of the flipping material transfer mold assembly 6 above, forming a seal and creating a closed air cavity (i.e., the initial mold cavity) for air blowing.

[0084] Air injection function: In the sealed position, through its internal channel, it connects to an external air pump and solenoid valve to precisely and stably inject compressed air into the glass droplet in the primary mold cavity, completing the first stage of blowing (initial blowing).

[0085] Reset and avoidance: After the air blowing is completed, the bottom mold lifting air injection rod 13 descends and disengages from the flipping and transferring mold assembly 6, making room for subsequent mold opening and blank transfer operations.

[0086] The initial mold assembly 3 includes an electric initial mold adjusting seat 21 that can be moved and adjusted on the initial mold frame 1. An initial mold mounting rod 17 is fixed on the electric initial mold adjusting seat 21. A plurality of initial mold bodies 16 are provided on the initial mold mounting rod 17. The initial mold bodies 16 are located above the bottom mold fixing seat 14 at the corresponding positions.

[0087] The electric adjustment seat 21 of the initial mold can be moved and adjusted on the initial mold frame 1. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the initial mold assembly 3 in three-dimensional space can be precisely controlled. Precise alignment: This ensures that the primary mold body 16 can be accurately positioned and tightly abut against the flipping and transferring mold assembly 6 below, forming a seal.

[0088] Precise alignment: This ensures that the opening above the primary mold body 16 can accurately align with and be sealed by the primary air injection top mold assembly 5.

[0089] Quick changeover: When producing bottle shapes of different specifications, the position of the entire initial mold assembly 3 can be quickly adjusted by electric adjustment to adapt to the new mold size, ensuring precise coordination with other components in the system (such as material injection, transfer, and gas injection), greatly improving the flexibility and efficiency of production.

[0090] The primary mold body 16 contains a preset primary blank cavity. When it is driven to the working position by the primary mold electric adjustment seat 21 and closed with the upper and lower primary gas injection top mold assembly 5 and the flipping transfer mold assembly 6, it together forms a closed primary mold cavity. The primary mold cavity is the space in which the glass droplet is formed into a primary blank in the first stage of blowing (initial blowing).

[0091] The injection mold assembly 4 includes an electric injection mold adjusting seat 20 that can be moved and adjusted on the initial mold frame 1. An injection mold mounting rod 18 is fixed on the electric injection mold adjusting seat 20. A plurality of injection mold bodies 19 are provided on the injection mold mounting rod 18. The injection mold bodies 19 are located above the corresponding initial mold bodies 16.

[0092] The electric adjustment seat 20 of the injection mold can be moved and adjusted on the initial mold base 1. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the injection mold assembly 4 in three-dimensional space can be precisely controlled. Precise alignment: This ensures that the outlet below the injection mold body 19 is precisely aligned and tightly abuts against the inlet above the primary mold body 16, forming a continuous glass liquid flow channel and preventing droplets from splashing or adhering to the seams.

[0093] Collaborative Changeover: When changing bottle type and simultaneously adjusting the position of the initial mold assembly 3, the injection mold assembly 4 can be adjusted in conjunction with its injection mold electric adjustment seat 20 to always maintain precise alignment with the initial mold. This ensures that molds of different sizes can obtain accurate injection, which is the key to achieving rapid production changeover and improving production line flexibility.

[0094] The injection mold body 19 has a cavity inside, which acts like a funnel to receive high-temperature glass droplets of a specific weight falling from the feeder and guide them into the primary mold body 16 directly below.

[0095] The initial gas injection ejector assembly 5 includes an electric adjusting seat 25 for the initial ejector that can be moved and adjusted on the initial mold frame 1. An initial ejector mounting rod 23 is fixed on the electric adjusting seat 25. The initial ejector mounting rod 23 is provided with an injection connector 22 and several initial gas injection ejector heads 24. The initial gas injection ejector heads 24 are located above the corresponding positions of the initial mold body 16. The lower end of the injection connector 22 is connected to the initial gas injection ejector head 24 through a pipe. The upper end of the injection connector 22 is connected to an external air pump through a solenoid valve.

[0096] The electric adjustment seat 25 of the initial mold can be moved and adjusted on the initial mold frame 1. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the initial air injection mold assembly 5 in three-dimensional space can be precisely controlled. Injection Position: Precise movement allows the initial gas injection ejector head 24 to move to and seal the upper end of the injection mold assembly 4. Gas is then injected into the initial mold body 16 through the gas injection connector 22 and internal pipes. The air pressure forces the newly fallen glass droplet downwards, ensuring it is stably, fully, and evenly distributed on the bottom of the initial mold and the transfer mold assembly, thus forming an ideal blank base for subsequent blowing. This adjustment function also serves for rapid mold changeover, allowing for synchronous adjustment with other components in the system to ensure fitting accuracy.

[0097] Sealing position: After the injection mold assembly 4 is removed, it can move precisely again. The initial injection ejector head 24 moves to and seals the upper opening of the initial mold assembly 3, forming a seal. At this time, its air holes are blocked by the mold structure, and it no longer blows air directly. At this time, the initial injection ejector head 24 forms a sealing cover, which together with the initial mold assembly 3 below and the flipping transfer mold assembly 6 constitutes a completely closed initial mold cavity. The initial mold cavity is a necessary prerequisite for the subsequent low-pressure air blowing by the initial injection bottom mold assembly 2 to form a preliminary blank with uniform wall thickness.

[0098] The flipping and transferring mold assembly 6 includes an electric flipping base 28. A flipping mounting rod 26 and a limiter 27 are fixedly mounted on the flipping shaft of the electric flipping base 28. Several transferring mold bodies 29 are mounted on the flipping mounting rod 26. In the initial position, the transferring mold bodies 29 are located above the bottom mold fixing base 14 at the corresponding position. After the electric flipping base 28 is flipped 180 degrees, the transferring mold bodies 29 are located between the molding and gas injection top mold assembly 7 and the molding mold assembly 10.

[0099] Initial position: During the initial molding stage, the transfer mold body 29 is located between the initial gas injection bottom mold assembly 2 directly below it and the initial mold assembly 3 directly above it. At this time, it is in close contact with the upper and lower molds, forming the bottom of the initial mold cavity together; its inner cavity shape directly participates in forming the bottom outline of the initial blank and reliably receives the glass droplets and blowing pressure from above.

[0100] The rotating shaft of the electric rotating base 28 drives all the material transfer mold bodies 29 to move synchronously via the rotating mounting rod 26.

[0101] Clamping and release: After the initial mold is blown and the surrounding molds are opened, the transfer mold body 29 is usually equipped with a clamping mechanism (such as a vacuum suction cup or gripper) that can firmly hold the initial mold blank.

[0102] The electric tilting seat 28 drives the transfer mold body 29 to rotate 180 degrees in the opposite direction, accurately transporting the preform blank from the preform mold holder 1 station to the forming mold holder 9 station, and positioning it between the forming mold assembly 10 and the forming gas injection ejector assembly 7. The preform blank is moved to the forming mold assembly 10, the forming mold assembly 10 clamps the preform blank, the transfer mold body 29 releases the preform blank, and the electric tilting seat 28 rotates 180 degrees in the forward direction, driving the empty transfer mold body 29 back to the initial position, ready to receive the next preform blank, and start a new work cycle.

[0103] The molding gas injection ejector assembly 7 includes a molding ejector electric adjustment seat 33 that can be moved and adjusted on the molding mold frame 9. A molding ejector mounting rod 34 is fixed on the molding ejector electric adjustment seat 33. A plurality of molding gas injection ejector heads 32 are provided on the molding ejector mounting rod 34. Each molding gas injection ejector head 32 is provided with a lifting and adjusting ejector lifting gas injection rod 31. The molding ejector electric adjustment seat 33 is provided with a second gas injection connector 30. The lower end of the second gas injection connector 30 is connected to the plurality of ejector lifting gas injection rods 31 through a pipe. The upper end of the second gas injection connector 30 is connected to an external air pump through a solenoid valve.

[0104] The electric adjusting seat 33 of the molding top mold can be moved and adjusted on the molding mold frame 9. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the molding gas injection top mold assembly 7 in three-dimensional space can be precisely controlled. Ensure that the molding injection ejector head 32 can move precisely and abut against the upper opening of the molding mold assembly 10; this adjustment function also serves quick changeover, and when changing the bottle type, it can be adjusted synchronously with other components to ensure precise fit of the sealing surface.

[0105] When the molding gas injection top mold assembly 7 moves to the working position, its molding gas injection top mold head 32 forms a seal with the upper end of the molding mold assembly 10. At the same time, the top mold lifting gas injection rod 31 inside descends, passes through and extends out of the top mold head, and directly inserts into and seals the bottle mouth of the preform transferred from the flipping material transfer mold assembly 6.

[0106] Establishing a high-pressure gas path: The downward movement of the top mold lifting air injection rod 31 forms a unique and sealed high-pressure air intake channel with the bottle mouth of the billet. The high-pressure gas is collected through the second air injection joint 30 and the internal pipe to each top mold lifting air injection rod 31, and then precisely and stably injected directly into the interior of the billet.

[0107] Final blow shaping: The pressure injected in this stage is much higher than that in the initial blow stage; the high pressure forces the heated and softened glass preform to expand fully in all directions until it is completely attached to the inner wall of the molding mold assembly 10, thereby replicating the precise inner cavity shape of the mold and completing the final shaping of the bottle body and the shaping of surface details.

[0108] Reset and avoidance (cycle preparation): After the final blowing is completed, the top mold lifting and air injection rod 31 first rises and disengages from the bottle mouth of the preform. Then, the entire molding air injection top mold assembly 7 moves, retracts, and resets, making room for the subsequent clamping and transferring assembly 8 to enter and remove the formed glass bottle.

[0109] The clamping and transferring assembly 8 includes a movable and adjustable electric transfer seat 36 on the forming mold frame 9, an electric rotating seat 37 is provided on the electric transfer seat 36, and a plurality of electric grippers 35 are provided on the electric rotating seat 37.

[0110] The electric transfer adjustment seat 36 can be moved and adjusted on the forming mold frame 9. The movement and adjustment include but are not limited to lifting, moving forward, backward, left and right. Through electric adjustment, the position of the clamping and transferring component 8 in three-dimensional space can be precisely controlled. After the molding injection top mold assembly 7 is reset and the molding mold assembly 10 is opened, the transfer electric adjustment seat 36 drives the entire assembly to move, so that the electric gripper 35 is precisely positioned and enters the mold above the already shaped glass bottle.

[0111] The electric gripper 35 performs the gripping action, firmly and stably grasping the neck or body of the glass bottle (usually the neck to avoid damaging the bottle surface), preparing it for transfer.

[0112] After clamping the glass bottle, the electric rotary seat 37 drives the entire clamping mechanism to rotate by a specific angle (e.g., 90 degrees or 180 degrees, depending on the layout of the conveyor chain), quickly transporting the glass bottle from the molding station located on the molding mold 9 to the top of the adjacent conveyor chain.

[0113] Once the glass bottle reaches the designated position, the electric gripper 35 releases, smoothly releasing the finished glass bottle onto the conveyor chain for subsequent annealing or testing processes.

[0114] After the bottle is released, the electric rotary seat 37 rotates in the opposite direction, and at the same time the electric adjustment seat 36 moves in coordination, driving the empty electric gripper 35 back to the standby position above the molding die, ready to execute the next work cycle.

[0115] The molding die assembly 10 includes a molding die electric adjustment seat 40 that can be moved and adjusted on the molding die frame 9. A molding die mounting rod 39 is fixed on the molding die electric adjustment seat 40. A plurality of molding die bodies 38 are provided on the molding die mounting rod 39. The molding die bodies 38 are located above the molding venting bottom die 11 at the corresponding position. The interior of the molding die body 38 is provided with distributed cooling channels, through which a constant temperature cooling medium is introduced to maintain the surface temperature of the mold cavity at 200-300℃ with a fluctuation range of ±5℃, so as to ensure thermal stability during the molding process.

[0116] The electric adjustment seat 40 for the molding mold can be moved and adjusted on the molding mold frame 9. The movement and adjustment include, but are not limited to, lifting, moving forward, backward, left and right. Through electric adjustment, the position of the molding mold assembly 10 in three-dimensional space can be precisely controlled. The entire molding die assembly 10 can be precisely controlled in space through electric adjustment, achieving two key seals: Precise alignment: This ensures that the molding body 38 can be accurately positioned and tightly abut against the molding and venting bottom mold 11 below, forming a sealed bottom of the mold.

[0117] Precise closure: Ensures that the molding body 38 of the left and right or front and back molds can be perfectly aligned to form a complete and seamless bottle cavity.

[0118] Quick changeover: When producing different bottle types, the position of the entire mold set can be quickly adjusted by electric adjustment to adapt to the size of the new mold and maintain precise fit with the molding injection top mold assembly 7 and the molding venting bottom mold 11, greatly improving the flexibility of the production line.

[0119] Final blow molding and venting: The molding die mounting rod 39 and the molding die body 38 are the core functional parts of the component.

[0120] The molding die mounting rod 39 provides solid structural support, ensuring that all molding die bodies 38 open and close synchronously and stably.

[0121] The inner cavity of the molding mold body 38 is engraved with the final, precise outline of the glass bottle; when it is closed with the molding venting bottom mold 11, it forms the final blow molding cavity.

[0122] During the final blowing stage, high-pressure gas causes the glass preform to adhere tightly to the inner wall of the mold cavity, completing the final shaping. During this process, the forming and venting bottom mold 11 may be equipped with tiny venting channels to expel air from the mold cavity, ensuring that the bottle surface is free of defects and can be fully fitted.

[0123] Mold opening and transfer (cycle preparation): After the final blow molding is completed, the electric adjustment seat 40 of the molding mold drives the molding mold body 38 to open, detaching from the formed glass bottle and the molding venting bottom mold 11, making room for the clamping and transfer component 8 to enter and take out the product.

[0124] The primary mold body 16 and the forming mold body 38 are made of H13 hot work die steel. Their cavity surfaces are coated with a diamond-like coating with a thickness of 2-4μm, in which the atomic percentage of tungsten is 5-10%, and the coefficient of friction of the coating surface is less than 0.15.

[0125] A lightweight glass bottle made by the above molding process has a bottom with a disc-shaped structure and annular reinforcing ribs. The ratio of the radius R of the cross-section of the annular reinforcing ribs to the diameter D of the bottle body satisfies: R / D=0.08-0.12.

[0126] The glass bottle has a gradually changing wall thickness from the body to the neck. The body wall thickness is 1.8-2.0 mm, gradually thinning to 1.2-1.4 mm towards the neck. The axial length L of the gradually changing wall thickness zone is 1.5-2.5 times the neck diameter d.

[0127] Comparative example (traditional process) Producing 500ml lightweight glass bottles for baijiu (Chinese liquor).

[0128] 1. Raw materials: Mixture: 55-65% quartz sand, 19-23% soda ash, 12-15% limestone and crushed glass. No crushed glass, ZrO2 and Li2O are added separately.

[0129] 2. One-step blowing: The temperature of the molten glass is controlled at 1500℃, and the blowing pressure is automatically adjusted to 0.5MPa. 3. The mold cooling system maintains the surface temperature of the mold cavity at 250±5℃.

[0130] 4. Annealing: An optimized annealing curve is used, and the cooling rate is set to 3.5℃ / min.

[0131] 5. Inspection and Feedback: The laser thickness gauge scans the wall thickness, with a target value of 2.4 mm and a tolerance of ±0.04 mm. Then, at least 30 glass bottles are randomly selected as test samples and subjected to a 1.5 m multi-angle drop test (they are considered qualified if they do not break when they land on a 3 cm thick steel plate) and a 65 kPa internal pressure resistance test (they are considered qualified if they do not break after 30 seconds).

[0132] 6. Results: The average weight of the obtained products was 520g, the pass rate of the 1.5m multi-angle drop test was ≥85%, the pass rate of the 65kPa internal pressure resistance test was 88%, and the production line qualification rate reached 86%.

[0133] Example 1: Producing 500ml lightweight glass bottles for baijiu (Chinese liquor).

[0134] 1. Raw materials: Mixture: 48% quartz sand, 12% soda ash, 4% limestone, of which 34% is crushed glass, with 1.5% ZrO2 and 0.5% Li2O added.

[0135] 2. Initial blowing: The temperature of the molten glass is controlled at 1500℃. According to the preset P1-μ relationship model, the initial blowing pressure is automatically adjusted to 0.25MPa to form the initial blank.

[0136] 3. Final blowing and mold control: The final blowing pressure is 0.48MPa, the mold opening and closing speed is controlled by a servo motor, and the mold cooling system maintains the mold cavity surface temperature at 200℃ with a fluctuation range of ±5℃.

[0137] 4. Annealing: An optimized annealing curve was used, and the cooling rate was set to 2.5℃ / min.

[0138] 5. Inspection and Feedback: The laser thickness gauge scans the wall thickness. The target value is 2.0 mm with a tolerance of ±0.04 mm. When the system detects that the wall thickness at the shoulder of the bottle is continuously too thin, it automatically increases the pressure of the corresponding blowing head by 0.01 MPa, gradually thinning the thickness to 1.4 mm towards the neck. Then, at least 30 glass bottles are randomly selected as test samples and subjected to a 1.5 m multi-angle drop test (the bottle is considered qualified if it does not break when it lands on a 3 cm thick steel plate) and a 65 kPa internal pressure resistance test (the bottle is considered qualified if it does not break after 30 seconds).

[0139] 6. Results: The average weight of the obtained products was 433g, the pass rate of the 1.5m multi-angle drop test was 88%, the pass rate of the 65kPa internal pressure resistance test was 90%, and the production line qualification rate reached 89%.

[0140] Example 2: Producing 500ml lightweight glass bottles for baijiu (Chinese liquor).

[0141] 1. Raw materials: Mixed material: 51% quartz sand, 12% soda ash, 4.5% limestone and crushed glass, of which crushed glass accounts for 29.5%, and 2% ZrO2 and 1% Li2O are added.

[0142] 2. Initial blowing: The temperature of the molten glass is controlled at 1550℃. According to the preset P1-μ relationship model, the initial blowing pressure is automatically adjusted to 0.3MPa to form the initial blank.

[0143] 3. Final blowing and mold control: The final blowing pressure is 0.5MPa, the mold opening and closing speed is controlled by a servo motor, and the mold cooling system maintains the mold cavity surface temperature at 250℃ with a fluctuation range of ±5℃.

[0144] 4. Annealing: An optimized annealing curve was used, and the cooling rate was set to 2.5℃ / min.

[0145] 5. Inspection and Feedback: The laser thickness gauge scans the wall thickness. The target value is 1.9mm with a tolerance of ±0.04mm. When the system detects that the wall thickness at the shoulder of the bottle is continuously too thin, it automatically increases the pressure of the corresponding blowing head by 0.01MPa, gradually thinning the thickness to 1.3mm towards the neck. Then, at least 30 glass bottles are randomly selected as test samples and subjected to a 1.5m multi-angle drop test (the bottle is considered qualified if it does not break when it lands on a 3cm thick steel plate) and a 65kPa internal pressure resistance test (the bottle is considered qualified if it does not break after 30 seconds).

[0146] 6. Results: The average weight of the obtained products was 416g, the pass rate of the 1.5m multi-angle drop test was 96%, the pass rate of the 65kPa internal pressure resistance test was 94%, and the production line qualification rate reached 93%.

[0147] Example 3: Producing 500ml lightweight glass bottles for baijiu (Chinese liquor).

[0148] 1. Raw materials: Mixed material: 50% quartz sand, 16% soda ash, 4.5% limestone and crushed glass, of which crushed glass accounts for 25%, and 3% ZrO2 and 1.5% Li2O are added.

[0149] 2. Initial blowing: The temperature of the molten glass is controlled at 1550℃. According to the preset P1-μ relationship model, the initial blowing pressure is automatically adjusted to 0.32MPa to form the initial blank.

[0150] 3. Final blowing and mold control: The final blowing pressure is 0.52MPa, the mold opening and closing speed is controlled by a servo motor, and the mold cooling system maintains the mold cavity surface temperature at 300℃ with a fluctuation range of ±5℃.

[0151] 4. Annealing: An optimized annealing curve was used, and the cooling rate was set to 2.5℃ / min.

[0152] 5. Inspection and Feedback: The laser thickness gauge scans the wall thickness. The target value is 1.8mm with a tolerance of ±0.04mm. When the system detects that the wall thickness at the shoulder of the bottle is continuously too thin, it automatically increases the pressure of the corresponding blowing head by 0.01MPa, gradually thinning the thickness to 1.2mm towards the neck. Then, at least 30 glass bottles are randomly selected as test samples for a 1.5m multi-angle drop test (the bottle is considered qualified if it does not break when it lands on a 3cm thick steel plate) and a 65kPa internal pressure resistance test (the bottle is considered qualified if it does not break after 30 seconds).

[0153] 6. Results: The average weight of the obtained products was 390g, the pass rate of the 1.5m multi-angle drop test was ≥89%, the pass rate of the 65kPa internal pressure resistance test was 91%, and the production line qualification rate reached 92%.

[0154] The performance comparison table for the above cases is as follows: Figure 11 As shown.

[0155] Depend on Figure 11 It can be seen that, except for the differences in the experimental data, all other conditions are the same in Examples 1 to 3. According to the experimental results, the glass bottles produced using this process are lightweight and have excellent performance, exceeding the performance levels of the comparative example (traditional process), resulting in significant economic and environmental benefits.

[0156] In summary, this process, through two-stage pressure blowing and the addition of special reinforcing agents, reduces the weight of the 500ml bottle by 20% while improving impact resistance by utilizing an optimized dish-shaped bottle bottom and annular reinforcing rib structure, thus solving the industry challenge of balancing lightweight and strength.

[0157] This process employs viscosity-based dynamic initial blowing pressure control and servo precision control of mold movement, combined with online laser thickness measurement and intelligent feedback system, to automatically fine-tune process parameters, ensuring uniform and accurate wall thickness (tolerance ±0.04mm), thereby improving product consistency and yield.

[0158] Each core module of this process is equipped with an electric three-dimensional adjustment mechanism, enabling rapid and precise mold alignment and coordinated adjustment. This reduces debugging time when changing bottle types, gives the production line a high degree of flexibility and adaptability, and meets the needs of multi-variety production.

[0159] This process integrates a complete quality monitoring system from molding to delivery, including high-precision wall thickness scanning, multi-angle drop testing (1.5m) and internal pressure resistance testing (≥65kPa), to ensure the mechanical reliability and durability of each product leaving the factory and eliminate defective products.

[0160] This process employs low-temperature, slow-speed annealing, reducing energy consumption by approximately 20%. The formulation incorporates up to 30% recycled glass, minimizing raw material consumption and waste. The lightweight design also directly reduces packaging and transportation costs, resulting in significant economic and environmental benefits.

[0161] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A lightweight two-stage blow molding process for glass bottles, characterized in that, Includes the following steps: S1. Raw material preparation and melting: Mix 48-58% quartz sand, 12-16% soda ash, 4-7% limestone and crushed glass by weight percentage, wherein the proportion of crushed glass is 25-35%. At the same time, add 1-3% ZrO2 as a reinforcing agent and 0.5-1.5% Li2O as a flux. Heat the mixture in a tank furnace to 1500-1550℃ to melt it into a uniform glass melt. S2. Feeding and initial molding: The glass liquid obtained in step S1 is cooled to a suitable molding temperature of 1150-1250℃. It is then cut into droplets of a specific weight by a feeder and falls into the initial mold cavity formed by the internal space of the initial gas injection top mold assembly (5), the initial mold assembly (3), and the flipping transfer mold assembly (6). Gas is injected into the interior of the initial mold assembly (3) through the initial gas injection top mold assembly (5), and the glass liquid droplets are squeezed downward to make the glass liquid droplets stable and fill downward. The initial gas injection bottom mold assembly (2) performs the first stage of gas injection and blowing from bottom to top: The initial blowing pressure P1 is dynamically adjusted according to the real-time viscosity μ of the glass liquid, satisfying the relationship: P1=kln(μ)+b, where k and b are coefficients determined by simulation optimization based on the bottle shape. P1 is maintained in a low pressure range of 0.28-0.32MPa for initial blowing to form the initial blank. S3. Shaping and strengthening: The transfer mold assembly (6) transfers the initial blank formed in the initial mold assembly (3) to the forming mold assembly (10). The forming gas injection top mold assembly (7) performs the second stage of gas injection blowing from top to bottom: the final blowing is performed at a higher pressure of 0.48-0.52MPa, so that the glass blank is tightly attached to the forming mold assembly (10) to complete the precise forming of the bottle body. During this process, the opening and closing speed of the mold is precisely controlled by the servo motor. S4. Annealing: The clamping and transferring assembly (8) transfers the formed glass bottle to the conveyor chain and sends it into the annealing furnace. The annealing furnace adopts a low-temperature annealing process, sets a specific annealing temperature curve, and reduces the cooling rate by 15-25% compared with the traditional process to eliminate internal stress. S5. Online inspection and sorting: After annealing, the glass bottles enter the inspection station. First, a laser thickness gauge is used to scan the bottle body from all directions, and products with unqualified wall thickness uniformity are rejected. Intelligent feedback control: When the system detects that the wall thickness of a specific area of ​​the bottle exceeds the tolerance range multiple times in a row, the central controller automatically fine-tunes the pressure parameters of the corresponding side blowing head or the closing gap of the mold to achieve closed-loop adaptive adjustment of process parameters. Subsequently, multi-angle drop tests and internal pressure resistance tests were conducted to ensure the mechanical strength of the product.

2. The lightweight two-stage blow molding process for glass bottles according to claim 1, characterized in that, When the system detects that the wall thickness of a specific area of ​​the bottle exceeds the tolerance range multiple times in a row, the central controller can automatically provide feedback and fine-tune the pressure parameters of the corresponding side blowing head or the closing gap of the mold.

3. The lightweight two-stage blow molding process for glass bottles according to claim 2, characterized in that, The laser thickness gauge has a measurement accuracy of ±0.02mm, a drop test height of 1.2m-1.5m, and an internal pressure test pressure of not less than 60kPa.

4. The lightweight two-stage blow molding process for glass bottles according to claim 3, characterized in that, The equipment used in steps S2 and S3 includes a preliminary mold frame (1), a material transfer mold assembly (6), a molding venting bottom mold (11), and a molding mold frame (9) arranged from left to right. The preliminary mold frame (1) is provided with a preliminary gas injection bottom mold assembly (2), a preliminary mold assembly (3), a material injection mold assembly (4), and a preliminary gas injection top mold assembly (5) arranged from bottom to top. The molding mold frame (9) is provided with a molding mold assembly (10) and a molding gas injection top mold assembly (7) arranged from bottom to top. The molding mold assembly (10) is located above the molding venting bottom mold (11). The molding mold frame (9) is also provided with a clamping and transferring assembly (8), which is located in front of the molding gas injection top mold assembly (7). The preliminary gas injection bottom mold assembly (2), the preliminary gas injection top mold assembly (5), the molding gas injection top mold assembly (7), and the molding venting bottom mold (11) are all connected to an external air pump through a solenoid valve.

5. The lightweight two-stage blow molding process for glass bottles according to claim 4, characterized in that, The initial mold injection base assembly (2) includes an electric adjustment base (15) that can be moved and adjusted on the initial mold frame (1). A base mold mounting rod (12) is fixed on the electric adjustment base (15). Several base mold fixing seats (14) are provided on the base mold mounting rod (12). An adjustable base mold lifting air injection rod (13) is provided inside the base mold fixing seat (14). The base mold lifting air injection rod (13) is connected to an external air pump through a solenoid valve. The initial mold assembly (3) includes an electric adjustment base (21) that can be moved and adjusted on the initial mold frame (1). An initial mold mounting rod (17) is fixed on the electric adjustment base (21). Several initial mold bodies (16) are provided on the initial mold mounting rod (17). The initial mold bodies (16) are located above the corresponding base mold fixing seats (14).

6. The lightweight two-stage blow molding process for glass bottles according to claim 5, characterized in that, The injection mold assembly (4) includes an electric injection mold adjusting seat (20) that can be moved and adjusted on the initial mold frame (1). An injection mold mounting rod (18) is fixed on the electric injection mold adjusting seat (20). A plurality of injection mold bodies (19) are provided on the injection mold mounting rod (18). The injection mold bodies (19) are located above the corresponding initial mold bodies (16). The initial mold ejector assembly (5) includes an electric initial mold ejector adjusting seat (25) that can be moved and adjusted on the initial mold frame (1). The initial mold electric adjustment base (25) is fixed with an initial mold mounting rod (23). The initial mold mounting rod (23) is equipped with an air injection connector (22) and several initial mold air injection mold heads (24). The initial mold air injection mold heads (24) are located above the corresponding initial mold body (16). The lower end of the air injection connector (22) is connected to the initial mold air injection mold head (24) through a pipe. The upper end of the air injection connector (22) is connected to the external air pump through a solenoid valve.

7. The lightweight two-stage blow molding process for glass bottles according to claim 6, characterized in that, The flipping and transferring mold assembly (6) includes an electric flipping base (28). A flipping mounting rod (26) and a limiter (27) are fixedly provided on the flipping shaft of the electric flipping base (28). Several transferring mold bodies (29) are provided on the flipping mounting rod (26). In the initial position, the transferring mold body (29) is located above the bottom mold fixing base (14) at the corresponding position. After the electric flipping base (28) is flipped 180 degrees, the transferring mold body (29) is located between the molding gas injection top mold assembly (7) and the molding mold assembly (10). The molding gas injection top mold assembly (7) includes a movable part on the molding mold frame (9). An adjustable forming top mold electric adjustment seat (33) is provided. A forming top mold mounting rod (34) is fixed on the forming top mold electric adjustment seat (33). A number of forming air injection top mold heads (32) are provided on the forming top mold mounting rod (34). The forming air injection top mold heads (32) are all equipped with adjustable top mold lifting air injection rods (31). An air injection connector two (30) is provided on the forming top mold electric adjustment seat (33). The lower end of the air injection connector two (30) is connected to the number of top mold lifting air injection rods (31) through a pipe. The upper end of the air injection connector two (30) is connected to an external air pump through a solenoid valve.

8. The lightweight two-stage blow molding process for glass bottles according to claim 7, characterized in that, The clamping and transferring assembly (8) includes a movable and adjustable electric adjustment seat (36) on the forming mold frame (9), an electric rotating seat (37) on the movable and adjustable electric adjustment seat (36), and a plurality of electric grippers (35) on the electric rotating seat (37); the forming mold assembly (10) includes a movable and adjustable forming mold electric adjustment seat (40) on the forming mold frame (9), a forming mold mounting rod (39) fixed on the forming mold electric adjustment seat (40), a plurality of forming mold bodies (38) on the forming mold mounting rod (39), the forming mold bodies (38) being located above the forming venting bottom mold (11) at the corresponding position, and the interior of the forming mold body (38) being provided with distributed cooling channels, through which a constant temperature cooling medium is introduced to maintain the surface temperature of the mold cavity at 200-300℃, with a fluctuation range of ±5℃, to ensure thermal stability during the forming process.

9. The lightweight two-stage blow molding process for glass bottles according to claim 8, characterized in that, The primary mold body (16) and the molding mold body (38) are made of H13 hot work die steel, and their cavity surfaces are coated with a diamond-like coating with a thickness of 2-4μm, wherein the atomic percentage of tungsten is 5-10%, and the coefficient of friction of the coating surface is less than 0.

15.

10. A lightweight glass bottle manufactured by the molding process described in claim 9, characterized in that, The bottom of the glass bottle has a dish-shaped structure with annular reinforcing ribs. The ratio of the radius R of the cross-section of the annular reinforcing ribs to the diameter D of the bottle body satisfies: R / D=0.08-0.

12. The wall thickness of the glass bottle from the bottle body to the neck is a gradual structure. The wall thickness of the bottle body is 1.8-2.0mm, gradually thinning to 1.2-1.4mm towards the neck, and the axial length L of the wall thickness gradient zone is 1.5-2.5 times the diameter d of the neck.

Images