Drum-type ultra-high speed linear molding assembly integrated system and method of medical elastomer gasket

Abstract

The application discloses a drum type ultra-high-speed linear forming and assembling integrated system and method for medical elastomer gaskets, comprising a ring-shaped cutting track, a ring-shaped assembling track and a synchronous driving system. A plurality of unit modules are arranged on the ring-shaped cutting track, and a cutting assembly and a pushing assembly are arranged on the unit modules, the cutting assembly being used for cutting and forming a rubber sheet roll into elastomer gaskets; the ring-shaped assembling track is used for conveying aluminum covers to a position-interacting area intersecting with the ring-shaped cutting track; the synchronous driving system controls the unit modules and the aluminum covers to synchronously arrive at the position-interacting area; the pushing assembly directly pushes the elastomer gaskets after cutting into the aluminum covers, and the cutting action and the pushing action are sequentially completed in the same motion cycle of the unit modules by the synchronous driving system. The application realizes synchronous linkage of cutting forming and assembling, eliminates the need for an intermediate transfer link, avoids pollution risks, and improves production efficiency and assembling reliability.

Description

Technical Field

[0001] This invention relates to the field of medical elastomer gasket molding and assembly technology, specifically a drum-type ultra-high-speed linear molding and assembly integrated system and method for medical elastomer gaskets. Background Technology

[0002] Prefilled pharmaceutical container assemblies are typically assembled from an elastomer gasket, an aluminum cap, and a type I borosilicate glass cartridge. The elastomer gasket is inserted inside the aluminum cap, and the two work together to provide a sealed packaging.

[0003] Currently, the production of medical elastomer gaskets mainly uses rubber sheet rolls as raw materials, which are formed by punching and cutting with a circular die. The gaskets obtained by punching are mostly cylindrical structures with a flat cylindrical outer wall. The aluminum cap is usually formed by stamping, and an inner cone angle with a certain curvature is formed at the bottom of the aluminum cap. When the flat cylindrical gasket is inserted into the aluminum cap with the inner cone angle, the apex of the gasket will be squeezed by the inner cone angle of the aluminum cap. Due to the lack of clearance, the gasket is prone to warping or unevenness, which directly affects the sealing reliability between the gasket and the aluminum cap.

[0004] In existing technologies, the cutting and forming of elastomer gaskets and the assembly of aluminum caps typically employ a separate process. This involves first cutting the rubber sheet on a separate cutting machine, collecting the gasket, and then transferring it to a separate assembly machine for assembly with the aluminum cap. This separate process presents several problems: First, the process is cumbersome, requiring multiple transfers of the gasket during cutting, collection, transfer, and repositioning, increasing operator contact with the product and raising the risk of contamination in a sterile and dust-free environment. Second, the production process is discontinuous, with the cutting and assembly machines located at different stations, resulting in material handling and long production times with low efficiency. Third, the gasket is prone to positional shifts and deformations during multiple transfers and repositioning processes, affecting the final assembly accuracy.

[0005] To address the aforementioned issues, one proposed improvement is to integrate the gasket cutting and forming process with the aluminum cap conveying, reducing intermediate steps. However, existing methods often employ independent conveyor belts or robotic arms for gasket transfer, resulting in time and positional differences between the cutting and assembly stations, hindering truly continuous production. Especially at ultra-high-speed production cycles (e.g., over 200 pieces per minute), achieving synchronized cutting and aluminum cap assembly, completing the entire process from rubber sheet to finished component within the same motion cycle, remains an unsolved technical challenge in this field.

[0006] Furthermore, in existing technologies, modules used for different processes such as cutting and assembly are usually driven independently. The movement speed and timing between modules are difficult to match precisely, which can easily lead to material accumulation or idle waiting, further restricting the improvement of production efficiency and assembly consistency. Summary of the Invention

[0007] The technical problem to be solved by this invention is to provide an integrated system and method for drum-type ultra-high-speed linear molding and assembly of medical elastomer gaskets. It aims to solve the technical problems of multiple gasket transfers, high risk of contamination, discontinuous production, low assembly efficiency and poor assembly accuracy caused by the separation of cutting and assembly processes in the existing split process. By using a synchronous drive system, the cutting and forming and the aluminum cap assembly are synchronized in the same motion cycle, so that the gasket is pushed into the aluminum cap immediately after cutting, without intermediate transfer links. This ensures the assembly quality and sealing reliability of the gasket and aluminum cap while achieving ultra-high-speed continuous production.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a drum-type ultra-high-speed linear molding and assembly integrated system for medical elastomer pads, including an annular cutting track, an annular assembly track and a synchronous drive system; The annular cutting track is provided with multiple unit modules arranged at intervals along the track direction. Each unit module is equipped with a cutting component and a pushing component. The cutting component is used to cut the rubber sheet roll into an elastomer gasket. The annular assembly track and the annular cutting track are spaced apart and form an alignment and handover area, which is used to transport the aluminum cover to the alignment and handover area; The synchronous drive system connects the annular cutting track and the annular assembly track, and is used to control the control module and the aluminum cover to arrive synchronously at the alignment and handover area. The push assembly directly pushes the cut elastomer gasket into the aluminum cover at the alignment and junction area. The cutting action of the cutting assembly and the pushing action of the push assembly are controlled by the synchronous drive system to be completed sequentially within the same motion cycle of the unit module. The arc-shaped conical surface of the elastomeric gasket fits into the inner conical angle of the aluminum cap at the bottom of the aluminum cap.

[0009] In a preferred embodiment, the unit module is provided with a first directional guide shaft, and a first guide wheel is mounted on the first directional guide shaft. The first guide wheel moves along a first trajectory line in the first guide rail to drive the cutting component to complete the cutting action. The unit module is also provided with a second directional guide shaft, on which a second guide wheel is installed. The second guide wheel moves along the second trajectory line in the second guide rail, driving the jacking assembly to complete the pushing action. The first trajectory line and the second trajectory line have different timing phases to achieve timing control of the cutting action first and the pushing action later.

[0010] In a preferred embodiment, the push assembly includes a top member with an adsorption structure at its front end, which maintains adsorption on the elastomeric gasket during the push-in process until the elastomeric gasket is pressed into the bottom of the aluminum cover and then the adsorption is released.

[0011] In a preferred embodiment, the annular assembly track is provided with a guide plate and a positioning plate. The guide plate is used to arrange the aluminum caps in a predetermined direction, and the positioning plate is used to position the aluminum caps at the alignment and junction area. The circular assembly track is also equipped with a support rod, which is used to lift the aluminum cover from the guide plate to the assembly station of the positioning plate.

[0012] In a preferred embodiment, the annular cutting track and the annular assembly track respectively include a first high-speed annular module, a second high-speed annular module, and a third high-speed annular module. The high-speed annular modules are connected by precision ball bearing guides for positioning, and each unit module has a floating structure design.

[0013] This invention also provides a drum-type ultra-high-speed linear molding assembly method for medical elastomer pads, comprising the following steps: S1. The rubber sheet roll is continuously fed into the cutting station of the circular cutting track, and the cutting component on the unit module cuts it into an elastomer gasket. S2. Continuously feed the aluminum cover into the circular assembly track and position it at the alignment and handover area; S3. After the cutting is completed, the unit module continues to move to the alignment and handover area, and the top push component pushes the cut elastomer gasket directly into the aluminum cover and compacts it. The cutting action in step S1 and the pushing action in step S3 are controlled by the synchronous drive system to be completed sequentially within the same motion cycle of the unit module. The interval between the completion of cutting in step S1 and the completion of pushing in step S3 does not exceed 1 second, thus achieving continuous and uninterrupted production.

[0014] In a preferred embodiment, the unit module is provided with a first directional guide shaft and a second directional guide shaft. The first directional guide shaft moves along a first trajectory line in the first guide rail to drive the cutting component to complete the cutting action in step S1. The second directional guide shaft moves along the second trajectory line in the second guide rail, driving the jacking assembly to complete the pushing action in step S3; The first trajectory line and the second trajectory line have different time phases.

[0015] In a preferred embodiment, the push assembly maintains its adsorption on the elastomeric pad during the pushing process in step S3 until the elastomeric pad is pressed into the bottom of the aluminum cover and then the adsorption is released.

[0016] In a preferred embodiment, a synchronous transmission mechanism is provided between the annular cutting track and the annular assembly track. The synchronous drive system matches the movement speed of the control unit module with the conveying speed of the aluminum cover through the synchronous transmission mechanism, so that the unit module and the aluminum cover arrive synchronously at the alignment and handover area and complete the alignment and handover. Moreover, the transmission ratio of the synchronous transmission mechanism is adjustable to adapt to aluminum covers and elastomer gaskets of different specifications.

[0017] In a preferred embodiment, the cutting action in step S1, the positioning action in step S2, and the pushing action in step S3 are continuously cycled within the same production cycle, forming a continuous cutting, positioning, and assembly cycle.

[0018] The present invention provides an integrated system and method for drum-type ultra-high-speed linear molding and assembly of medical elastomer pads. By adopting the above structure and method, it has the following beneficial effects: (1) By setting up a ring-shaped cutting track and a ring-shaped assembly track, and controlling their coordinated operation by a synchronous drive system, the elastomer gasket is directly pushed into the aluminum cap by the push assembly after cutting. The gasket does not need to go through intermediate steps such as collection, transfer, and repositioning during the entire process. Compared with the existing split-type process flow where the gasket needs to be transferred multiple times and the operator needs to come into contact with the product multiple times, the present invention significantly reduces the risk of contamination of pharmaceutical packaging products in a sterile environment, and is particularly suitable for the field of pre-filled packaging of biological agents with extremely high sterility requirements; (2) The cutting action of the cutting component and the pushing action of the pushing component are controlled to be completed sequentially within the same motion cycle of the unit module by the synchronous drive system. The interval between the completion of cutting and the completion of pushing does not exceed 1 second, forming a continuous cutting-positioning-assembly cycle. Compared with the separate process in the prior art where the cutting equipment and assembly equipment belong to different work stations and there is a material turnover link in the middle, the present invention realizes the continuous production of the entire process from rubber sheet roll to finished component, effectively solving the problems of excessive production time and discontinuous production method. The production capacity can reach 200 to 5000 pieces per minute. (3) A first directional guide shaft and a second directional guide shaft are set on the unit module, which move along the first trajectory line in the first guide rail and the second trajectory line in the second guide rail respectively. Through the differentiated design of the timing phase of the two trajectory lines, the sequential control of "cutting action first and pushing action later" is realized in a purely mechanical way. It does not need to rely on complex sensors and electrical control logic. It has a fast response speed, high action reliability, and can adapt to high-frequency reciprocating motion under ultra-high speed production cycle. (4) An adsorption structure is set at the front end of the top part to maintain the adsorption of the elastomer gasket during the pushing process until the gasket is pressed into the bottom of the aluminum cover and the adsorption is released. This design ensures that the gasket does not shift, flip or fall during the transfer from the cutting station to the aluminum cover station, ensuring that the gasket enters the aluminum cover in the correct posture, avoiding poor assembly caused by the gasket position offset, and improving the assembly accuracy and consistency. (5) A synchronous transmission mechanism is set between the circular cutting track and the circular assembly track, and the transmission ratio is adjustable. When producing aluminum caps and elastomer gaskets of different specifications, the speed of the unit module can be precisely matched with the conveying speed of the aluminum cap by adjusting the transmission ratio. This ensures that the alignment accuracy and timing coordination of cutting and assembly can be maintained when switching between different specifications of products. There is no need to replace the entire track system, which reduces the changeover time of the production line and lowers the equipment investment and maintenance costs. (6) The layout of the ring cutting track and the ring assembly track is adopted. The high-speed ring modules are connected by precision ball guide pillars. The unit module adopts a floating structure design. The ring track layout enables the equipment to achieve multi-station parallel operation in a limited space, which improves production efficiency. The precision ball guide pillar positioning connection ensures that the repeatability of each module can reach ±0.05mm. The floating module design enables each unit module to adapt to slight offset during movement, reduce rigid impact, extend the service life of the mold, and ensure the cutting and assembly accuracy under ultra-high frequency reciprocating motion. Attached Figure Description

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a diagram of the existing gasket structure.

[0020] Figure 2 This is a structural diagram of the aluminum cap.

[0021] Figure 3 This is a diagram showing the state of the existing gasket and aluminum cover after assembly.

[0022] Figure 4 This is a structural diagram of the large and small head gasket product cut and shaped according to the present invention.

[0023] Figure 5 This is an assembly diagram of the cut and molded large and small head gasket products of this invention and the aluminum cover.

[0024] Figure 6 This is a schematic diagram of the structure of the unit module of the present invention.

[0025] Figure 7 This is a schematic diagram of the structure of multiple high-speed ring modules working together in this invention.

[0026] Figure 8 This is a schematic diagram showing the positional relationship between the guide rail and the trajectory line of the present invention.

[0027] Figure 9 This is a schematic diagram of the high-speed ring module of the present invention.

[0028] Figure 10 This is a schematic diagram of the molding station layout and hole structure of the present invention.

[0029] In the diagram: 1. First directional guide shaft; 2. Guide post; 3. Fixing plate; 4. Elastic component; 5. Second directional guide shaft; 6. Fixing plate; 7. Top piece; 8. Fixing plate; 9. Parting tool; 10. Cutting plate; 11. Elastomer rubber product; 12. Support rod; 13. Positioning plate; 14. Guide plate; 15. Fixing plate; 16. Screw; 17. Molding station layout; 18. Hole type; 19. First guide rail; 20. Second guide rail; 22. First high-speed ring module; 23. Second high-speed ring module; 24. Third high-speed ring module; 26. Aluminum cover; 27. Elastomer gasket; 28. Rubber non-vulcanized molding surface; 29. ​​Inner cone angle of aluminum cover; 30. First trajectory line; 31. Second trajectory line; 32. Unit module. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0031] Example 1: See Figures 6 to 10 This invention provides a drum-type ultra-high-speed linear forming and assembly integrated system for medical elastomer gaskets, including an annular cutting track, an annular assembly track, and a synchronous drive system. The annular cutting track and the annular assembly track are spaced apart, forming an alignment and junction area between them.

[0032] Multiple unit modules 32 are spaced apart along the track direction on the annular cutting track. Each unit module 32 is equipped with a cutting component and a pushing component. An annular assembly track and an annular cutting track are spaced apart and form an alignment and transfer area for conveying the aluminum cover 26 to the alignment and transfer area. A synchronous drive system connects the annular cutting track and the annular assembly track to control the synchronous arrival of the unit module 32 and the aluminum cover 26 at the alignment and transfer area. At the alignment and transfer area, the pushing component directly pushes the cut elastomer gasket 27 into the aluminum cover 26. The cutting action of the cutting component and the pushing action of the pushing component are controlled by the synchronous drive system and completed sequentially within the same motion cycle of the unit module 32.

[0033] The synchronous drive system preferably uses a vector control permanent magnet synchronous motor, with a positioning accuracy of ±0.05mm.

[0034] See Figure 6The unit module 32 is equipped with a first directional guide shaft 1 and a second directional guide shaft 5. A first guide wheel is mounted on the first directional guide shaft 1, and moves along a first trajectory line 30 in the first guide rail 19, driving the cutting assembly to complete the cutting action. A second guide wheel is mounted on the second directional guide shaft 5, and moves along a second trajectory line 31 in the second guide rail 20, driving the pushing assembly to complete the pushing action. The timing phases of the first trajectory line 30 and the second trajectory line 31 are different to achieve timing control where the cutting action precedes the pushing action.

[0035] See Figure 6 The unit module 32 includes a module body, on which a first directional guide shaft 1 and a second directional guide shaft 5 are provided. The first directional guide shaft 1 is mounted on the upper end of the unit module 32 via a fixing plate 3, and the second directional guide shaft 5 is mounted on the corresponding position of the unit module 32 via a fixing plate 6. Guide posts 2 are provided on both sides of the unit module 32 to lock the degree of freedom of the unit module 32, ensuring that the cutting edge of the parting tool 9 always moves horizontally and vertically downward during the cutting process, avoiding cutting deviation. An elastic component 4 is installed between the fixing plate 3 and the fixing plate 6, and is used to drive the fixing plate 6 and the top piece 7 installed on it to return to the upper position after cutting. The fixing plate 8 is provided at the lower end of the unit module 32 for mounting the cutting support plate 10. The fixing plate 15 is provided at the bottom of the unit module 32 for mounting the support rod 12 on the unit module 32. Screws 16 fix the fixing plates 3, 6, 8, and 15 to the corresponding positions of the unit module 32.

[0036] The cutting assembly includes a parting tool 9 and a cutting plate 10. The parting tool 9 can be a punch or a die, and the cutting plate 10 can be a die or a perforated plate. The rubber sheet roll is cut between the two to form an elastomer gasket 27. After the cutting assembly cuts the rubber sheet roll, it forms an individual elastomer rubber product 11. This elastomer rubber product 11 is the cut elastomer gasket 27, which has an arc-shaped conical surface and is used for subsequent insertion into the aluminum cap 26. For ease of description, this elastomer rubber product 11 will be referred to as the elastomer gasket 27 below.

[0037] The cutting edge angle of the parting tool 9 in the cutting assembly is preferably 10° to 35°. When the cutting edge angle is less than 10°, the cutting edge strength is insufficient and it is easy to chip during high-speed punching; when the cutting edge angle is greater than 35°, the cutting resistance increases, which can easily lead to unevenness of the rubber sheet cutting surface and affect the sealing performance of the gasket and the aluminum cover.

[0038] The push assembly includes a pusher 7, whose front end has an adsorption structure that maintains adsorption on the elastomer gasket 27 during the push-in process until the elastomer gasket 27 is pressed into the bottom of the aluminum cover 26, at which point the adsorption is released. The adsorption structure can be a vacuum adsorption method, with the timing of adsorption and desorption controlled by an external air circuit; it can also be an electrostatic adsorption or micro-suction cup structure, depending on the rubber sheet material and production environment. The design of the pusher 7 ensures that the gasket does not shift, flip, or fall off during the transfer from the cutting station to the aluminum cover station.

[0039] See Figure 7 and Figure 9 The annular cutting track and the annular assembly track each include a high-speed annular module 22, a high-speed annular module 23, and a high-speed annular module 24. The high-speed annular modules 22, 23, and 24 have identical mechanisms. The high-speed annular modules are connected and positioned by precision ball bearing guides. Each unit module 32 features a floating structure design, enabling it to adapt to minute offsets during movement, reducing rigid impacts and extending the mold's service life.

[0040] A synchronous transmission mechanism is provided between the circular cutting track and the circular assembly track. The synchronous drive system matches the movement speed of the control module 32 with the conveying speed of the aluminum cover 26 through the synchronous transmission mechanism, so that the unit module 32 and the aluminum cover 26 arrive synchronously at the alignment and handover area and complete the alignment and handover. The transmission ratio of the synchronous transmission mechanism is adjustable to adapt to different specifications of aluminum covers 26 and elastomer gaskets 27. For example, when producing gaskets of different diameters or thicknesses, adjusting the transmission ratio can maintain the alignment accuracy and timing coordination of cutting and assembly without replacing the entire track system.

[0041] Example 2: See Figures 6 to 10 The present invention also provides a drum-type ultra-high-speed linear molding and assembly method for medical elastomer pads, comprising the following steps: S1. The rubber sheet roll is continuously fed into the cutting station of the annular cutting track, where the cutting assembly on the unit module 32 cuts it into an elastomer gasket 27. Specifically, the unit module 32 moves along the annular cutting track, and the first guide wheel on the first directional guide shaft 1 first enters the first trajectory line 30 of the first guide rail 19, driving the parting tool 9 to move downwards, cooperating with the cutting plate 10 to punch and cut the rubber sheet. The blade angle is preferably 10° to 35°, which ensures the flatness of the cut surface and extends the service life of the die within this angle range.

[0042] S2. The aluminum cover 26 is continuously fed into the circular assembly track and positioned at the alignment and handover area. Specifically, the aluminum cover 26 is placed into the hopper of the guide plate 14 in directional order by the flexible vibration module. The guide plate 14 arranges the aluminum cover 26 in a predetermined direction, and then the support rod 12 lifts the aluminum cover 26 from the guide plate 14 to the assembly station of the positioning plate 13.

[0043] S3. After cutting, the unit module 32 continues to move to the alignment and handover area, where the push assembly directly pushes the cut elastomer pad 27 into the aluminum cover 26 and compacts it. Specifically, the second guide wheel on the second directional guide shaft 5 enters the second trajectory line 31 of the second guide rail 20, driving the top member 7 to move downward. The adsorption structure at the front end of the top member 7 adsorbs the cut elastomer pad 27, pushes it out from the cutting station and directly presses it into the aluminum cover 26 pre-positioned in the alignment and handover area until the arc-shaped conical surface of the elastomer pad 27 is tightly fitted with the inner cone angle 29 of the bottom of the aluminum cover 26, completing the compaction.

[0044] The cutting action in step S1 and the pushing action in step S3 are controlled by the synchronous drive system and completed sequentially within the same motion cycle of the unit module 32. The interval between the completion of cutting in step S1 and the completion of pushing in step S3 does not exceed 1 second, preferably not more than 0.5 seconds, thereby achieving continuous uninterrupted production. The cutting action in step S1, the positioning action in step S2, and the pushing action in step S3 are continuously cycled within the same production cycle, forming a continuous cutting, positioning, and assembly cycle.

[0045] Steps S1, S2, and S3 described above can all be performed in a sterile environment with a cleanliness level of ISO 7 or higher, enabling unmanned and remotely controlled operation throughout the entire production process. The entire cutting, transfer, and assembly process is completed continuously within one motion cycle of a single unit module 32, achieving continuous production from rubber sheet rolls to finished components, with a capacity of 200 to 5000 units per minute.

[0046] The following is combined Figure 6 and Figure 8 The timing control principle of the present invention will be further explained.

[0047] When the unit module 32 moves along the annular cutting track, the first guide wheel on the first directional guide shaft 1 first enters the first trajectory line 30 of the first guide rail 19. The first trajectory line 30 guides the first directional guide shaft 1 to move downwards, driving the parting tool 9 to move downwards and punching and cutting the rubber sheet roll. After cutting, the unit module 32 continues to move along the track. When it reaches the alignment and junction area, the second guide wheel on the second directional guide shaft 5 enters the second trajectory line 31 of the second guide rail 20. Because the timing phases of the first trajectory line 30 and the second trajectory line 31 are different, the second trajectory line 31 guides the second directional guide shaft 5 to move downwards lagging behind the first directional guide shaft 1, driving the top member 7 to push out the already cut elastomer gasket 27. Through the timing phase difference design of the two trajectory lines, the sequential control of "cutting first, pushing in later" is achieved in a purely mechanical way, without relying on complex sensors and electrical control logic.

[0048] It should be understood that the specific shape and length of the first trajectory line 30 and the second trajectory line 31 can be adapted to the cutting time and conveying distance of products of different specifications, as long as the two meet the sequential order of "cutting completed → pushing completed" and the interval time does not exceed 1 second.

[0049] The following is combined Figure 6 The adsorption control principle of the present invention will be further explained.

[0050] The adsorption structure at the front end of the top piece 7 activates adsorption when the top piece 7 moves downwards and contacts the cut elastomer gasket 27, thus adsorbing and fixing the elastomer gasket 27 to the front end of the top piece 7. As the top piece 7 continues to move downwards and pushes the elastomer gasket 27 into the aluminum cover 26, the adsorption structure maintains its adsorption state, ensuring that the gasket does not shift or flip. Once the top piece 7 has pressed the elastomer gasket 27 into the bottom of the aluminum cover 26, and the arc-shaped conical surface is tightly fitted with the inner conical angle 29 of the aluminum cover, the adsorption structure releases its adsorption, and the top piece 7 returns to its original position.

[0051] The adsorption and desorption can be controlled by the timing of an external pneumatic system. Specifically, a pneumatic channel can be installed inside the top component 7, connected to an external vacuum generator, and the opening and closing of the vacuum channel can be controlled by a solenoid valve. The timing of adsorption initiation and desorption is related to the position of the unit module 32. Specifically, a position sensor can be used to detect when the unit module 32 reaches a predetermined position and send a signal to control the solenoid valve. The adsorption holding time covers the entire process from the top component 7 contacting the elastomer gasket 27 to the gasket being pressed into the bottom of the aluminum cover 26, ensuring the positional accuracy of the gasket during the transfer process.

[0052] Explanation of the diversity of molding station layout: See Figure 10The forming station layout 17 can be configured in various styles and quantities according to the actual needs of product diversity. Hole types 18 can be circular, inner / outer annular, polygonal, irregular, etc., with a product shape quantity ranging from 1 to 200. For example, when producing large-sized gaskets, a smaller number of forming stations (e.g., 1-10) can be used; when producing small-sized gaskets, a larger number of forming stations (e.g., 50-200) can be used to achieve a material utilization rate of 55%-70%. Multiple unit modules 32 are arranged at intervals along the annular cutting track. Each unit module 32 can be replaced independently. When a unit module 32 wears out or requires a change in product specifications, only that unit module 32 needs to be replaced, eliminating the need to stop the entire line for replacement, thus reducing production line downtime and changeover time.

[0053] Material utilization rate explanation: This invention achieves a material utilization rate of 55% to 70% through the rational design of the forming station layout 17. Compared with the existing technology that uses a circular die to punch one by one, the present invention allows multiple unit modules 32 to operate in parallel on the annular cutting track. The forming station layout 17 can be optimized according to the width of the rubber sheet roll and the outer diameter of the gasket. The holes 18 are arranged in an alternating manner to reduce the proportion of scrap material, thereby ensuring a high material utilization rate while achieving ultra-high-speed production.

[0054] The following is combined Figures 6 to 10 The overall operation process of this invention is described in detail.

[0055] The rubber sheet roll is continuously fed into the annular cutting track, and the unit module 32 moves along the annular cutting track. Each time the unit module 32 reaches a cutting station, the first guide wheel on the first directional guide shaft 1 moves along the first trajectory line 30 in the first guide rail 19, driving the parting tool 9 to move downwards. This parting tool, in conjunction with the cutting support plate 10, punches and cuts the rubber sheet, forming an elastomer pad 27 with an arc-shaped conical surface. After cutting, the elastomer pad 27 remains attached to the rubber sheet roll and continues to move with the unit module 32.

[0056] Meanwhile, the aluminum cover 26 is placed into the hopper of the guide plate 14 in directional sequence by the flexible vibration module, and the guide plate 14 arranges the aluminum cover 26 in a predetermined direction. When the unit module 32 continues to move to the alignment and handover area, the second guide wheel on the second directional guide shaft 5 moves along the second trajectory line 31 in the second guide rail 20, driving the top member 7 to move downward. The adsorption structure at the front end of the top member 7 adsorbs the elastic pad 27 attached to the rubber sheet, peels it off the rubber sheet, and pushes it directly into the interior of the aluminum cover 26 pre-positioned at the positioning plate 13. The top member 7 continues to press the elastic pad 27 into the bottom of the aluminum cover 26, so that the arc-shaped conical surface of the elastic pad 27 fits tightly with the inner cone angle 29 of the bottom of the aluminum cover 26, completing the compaction. After compaction, the top member 7 releases the adsorption and returns to its original position, and the assembled finished product is output from the ring assembly track.

[0057] The entire process of cutting, transferring, and assembling is completed continuously within one motion cycle of a single unit module 32, with the entire cycle not exceeding 1 second, preferably not exceeding 0.5 seconds. This achieves integrated, continuous, and ultra-high-speed production of medical elastomer gaskets from rubber sheet rolls to finished aluminum caps.

[0058] In the above embodiments, the parting tool 9 can be either a punch or a die, and the cutting plate 10 can be either a die or a perforated plate, depending on the actual situation. The two work together to achieve punching and parting cutting of the elastomeric rubber parts.

[0059] In the above embodiments, the hopper structure of the guide plate 14 can be adaptively designed according to the external dimensions of the aluminum cover 26 to accommodate aluminum covers 26 of different specifications.

[0060] In the above embodiments, each high-speed ring module 22, 23, and 24 has the same structure. The modules are connected by precision ball bearing guides. The floating structure design of the unit module 32 enables each unit module 32 to adaptively offset slightly during high-speed movement, ensuring the cutting and assembly accuracy under ultra-high frequency reciprocating motion.

Claims

1. A drum-type ultra-high-speed linear molding and assembly integrated system for medical elastomer gaskets, characterized in that: Includes a circular cutting track, a circular assembly track, and a synchronous drive system; The annular cutting track is provided with multiple unit modules (32) arranged at intervals along the track direction. The unit modules (32) are equipped with cutting components and pushing components. The cutting components are used to cut the rubber sheet roll into an elastomer gasket (27). The annular assembly track and the annular cutting track are spaced apart and form an alignment and handover area, which is used to transport the aluminum cover (26) to the alignment and handover area; The synchronous drive system connects the annular cutting track and the annular assembly track, and is used to control the control module (32) and the aluminum cover (26) to arrive synchronously at the alignment junction area; The push assembly directly pushes the cut elastomer gasket (27) into the aluminum cover (26) at the alignment and junction area. The cutting action of the cutting assembly and the pushing action of the push assembly are controlled by the synchronous drive system to be completed sequentially within the same motion cycle of the unit module (32). The arc-shaped conical surface of the elastomer gasket (27) fits into the inner cone angle (29) of the aluminum cap (26) at the bottom of the inner part of the aluminum cap.

2. The drum-type ultra-high-speed linear molding and assembly integrated system for medical elastomer pads according to claim 1, characterized in that: The unit module (32) is provided with a first directional guide shaft (1), and a first guide wheel is installed on the first directional guide shaft (1). The first guide wheel moves along the first trajectory line (30) in the first guide rail (19) to drive the cutting component to complete the cutting action. The unit module (32) is also provided with a second directional guide shaft (5), and a second guide wheel is installed on the second directional guide shaft (5). The second guide wheel moves along the second trajectory line (31) in the second guide rail (20) to drive the jacking assembly to complete the pushing action. The timing phases of the first trajectory line (30) and the second trajectory line (31) are different, so as to realize the timing control of the cutting action first and the pushing action later.

3. The drum-type ultra-high-speed linear molding and assembly integrated system for medical elastomer pads according to claim 1, characterized in that: The push assembly includes a top piece (7), the front end of which is provided with an adsorption structure to maintain the adsorption of the elastomer pad (27) during the push-in process until the elastomer pad (27) is pressed into the bottom of the aluminum cover (26) and then the adsorption is released.

4. The drum-type ultra-high-speed linear molding and assembly integrated system for medical elastomer pads according to claim 1, characterized in that: The circular assembly track is provided with a guide plate (14) and a positioning plate (13). The guide plate (14) is used to arrange the aluminum cover (26) in a predetermined direction, and the positioning plate (13) is used to position the aluminum cover (26) at the alignment junction area. The circular assembly track is also equipped with a support rod (12), which is used to lift the aluminum cover (26) from the guide plate (14) to the assembly station of the positioning plate (13).

5. The drum-type ultra-high-speed linear molding and assembly integrated system for medical elastomer gaskets according to claim 1, characterized in that: The annular cutting track and the annular assembly track respectively include a first high-speed annular module (22), a second high-speed annular module (23), and a third high-speed annular module (24). Each high-speed annular module is connected by a precision ball bearing guide post, and each unit module (32) is designed as a floating structure.

6. A drum-type ultra-high-speed linear molding assembly method for medical elastomer gaskets, characterized in that... Includes the following steps: S1. The rubber sheet roll is continuously fed into the cutting station of the circular cutting track, and the cutting component on the unit module (32) cuts it into an elastomer gasket (27). S2. The aluminum cap (26) is continuously fed into the circular assembly track and positioned at the alignment and handover area. S3. After the cutting is completed, the unit module (32) continues to move to the alignment and handover area, and the top push assembly pushes the cut elastomer gasket (27) directly into the aluminum cover (26) and compacts it. The cutting action in step S1 and the pushing action in step S3 are controlled by the synchronous drive system to be completed sequentially within the same motion cycle of the unit module (32). The interval between the completion of cutting in step S1 and the completion of pushing in step S3 does not exceed 1 second, so as to achieve continuous and uninterrupted production.

7. The drum-type ultra-high-speed linear molding assembly method for a medical elastomer gasket according to claim 6, characterized in that: The unit module (32) is provided with a first directional guide shaft (1) and a second directional guide shaft (5). The first directional guide shaft (1) moves along the first trajectory line (30) in the first guide rail (19) to drive the cutting component to complete the cutting action in step S1. The second directional guide shaft (5) moves along the second trajectory line (31) in the second guide rail (20) to drive the push assembly to complete the pushing action in step S3; The first trajectory line (30) and the second trajectory line (31) have different time phases.

8. The drum-type ultra-high-speed linear molding assembly method for a medical elastomer gasket according to claim 6, characterized in that: The push assembly maintains adsorption on the elastomer pad (27) during the push-in process in step S3 until the elastomer pad (27) is pressed into the bottom of the aluminum cover (26) and then the adsorption is released.

9. A drum-type ultra-high-speed linear molding and assembly integrated system for a medical elastomer pad according to any one of claims 1 to 5, characterized in that: A synchronous transmission mechanism is provided between the annular cutting track and the annular assembly track. The synchronous drive system matches the movement speed of the control module (32) with the conveying speed of the aluminum cover (26) through the synchronous transmission mechanism, so that the unit module (32) and the aluminum cover (26) arrive synchronously at the alignment and handover area and complete the alignment and handover. The transmission ratio of the synchronous transmission mechanism is adjustable to adapt to different specifications of aluminum covers (26) and elastomer gaskets (27).

10. A drum-type ultra-high-speed linear molding assembly method for a medical elastomer gasket according to any one of claims 6 to 8, characterized in that: The cutting action in step S1, the positioning action in step S2, and the pushing action in step S3 are continuously cycled within the same production cycle, forming a continuous cutting, positioning, and assembly cycle.

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