Adjustable-Throttle Preform Forming for Reduced-Air Blow Moulding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing blow-moulding machines face challenges in achieving efficient air recycling and reduced energy consumption while maintaining container quality, due to high pressure differences and manual adjustments of the throttle, leading to increased installation space and energy consumption.

Innovation Solution

A forming device with adjustable throttles and additional intermediate pressure stages, combined with a valve block design that includes five process valves, allows for optimized pressure control and reduced dead space, enabling faster and more efficient blow moulding with lower air consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the relief pressure is reduced to lower dead space volume, then air recycling efficiency improves, but the pressure difference between stages increases making recycling impossible

Engineering Contradiction:

Improveair recycling efficiencyVSAvoidpressure difference between stages

Core Design Contradiction:

Loss of energyVSStress or pressure

Solution Approach 1:

The patent introduces an additional intermediate pressure stage between the first and second pressure levels, dividing the pressure reduction process into smaller incremental steps. This segmentation allows air to be recycled through multiple smaller pressure differences rather than one large difference, making recycling feasible while maintaining efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The additional intermediate stage acts as a mediator pressure level that facilitates smooth transition between the first and second pressure stages. This intermediary stage enables air to flow from higher to lower pressure through controlled incremental steps, resolving the contradiction between recycling efficiency and pressure difference constraints.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If another intermediate stage is added to improve recycling, then air consumption efficiency improves, but installation space and dead space increase

Engineering Contradiction:

Improveair consumption efficiencyVSAvoidinstallation space

Core Design Contradiction:

Loss of energyVSVolume of stationary object

Solution Approach 1:

The patent integrates the additional intermediate stage into the existing valve block structure, merging multiple pressure control functions into a single compact unit. This combining approach achieves improved air recycling efficiency while minimizing the increase in installation space by consolidating components rather than adding separate external units.

Inventive Principle:

Principle #5Merging (Combining)

3Stress or pressure

If manual adjustment of the throttle is performed, then pressure control is achieved, but production stops and errors occur

Engineering Contradiction:

Improvepressure controlVSAvoidproduction continuity

Core Design Contradiction:

Stress or pressureVSProductivity

Solution Approach 1:

The system employs automated control mechanisms that self-regulate pressure without requiring manual intervention. The throttle and pressure stages are controlled through automated sequencing, allowing the system to maintain precise pressure control while continuing production without stops or human errors.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical adjustment with automated control systems, substituting human operation with mechanized or electronic control. This substitution maintains accurate pressure control while eliminating production stoppages and manual errors, thereby improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution achieves faster production times, improved container quality, and reduced energy consumption by optimizing pressure curves and minimizing dead space, allowing for high station outputs with minimal air usage.

Implementation Method 1

The process valves are suitable and intended to apply the plastic preform with different pressures P1, Pi, P+, P2

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 2

applying the plastic preforms with the pressurised flowable medium

Methodology Applied

Scientific EffectPressure increase: Pressure Increase

Data Source

PatentUS12403644B2Apparatus and method for forming plastic preforms into plastic containers with adjustable throttle

Publication Date: 2025.09.02 KRONES AG

AI summary

Apparatus for forming plastic preforms into plastic containers, having a forming device which has a plurality of forming stations each having a stretching bar for stretching the plastic preform and an application device act upon the plastic container with a flowable medium. The forming device has at least four pressure reservoirs for the flowable medium, which each have predetermined pressures, and a valve block with at least five process valves. The application device is configured for producing a fluid connection between the valve block and a mouth region of the plastic preform in order to act upon the plastic preforms with the pressurised flowable medium, and the process valves are configured to act upon the plastic preforms with different pressures, wherein at least one process valve is configured for producing a connection between the plastic preform and an environment.