Angled Bottle-Neck Forming Surfaces for Precise Glass Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing glass forming tools are inadequate for reliably achieving precise geometries, particularly for high-precision applications like medical containers, as they limit the achievable geometries and result in incomplete filling and defects.
Innovation Solution
A forming tool with slanted rotated forming surfaces and cutouts at specific angles (5-15 degrees and 60-85 degrees) allows for accurate glass deformation and distribution, reducing the risk of incomplete filling and defects, and enabling gentler shaping with reduced force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming tools with perpendicular forming surfaces are used, then the tool structure is simple, but the manufacturing precision and geometry accuracy are insufficient for high-precision applications
Solution Approach 1:
The forming surfaces are changed from perpendicular to the axis to slanted at specific angles (5-15 degrees for the first forming surface, 60-85 degrees for the second forming surface). This parameter change in the forming surface geometry enables precise control over glass flow and distribution, achieving accurate geometries and thin cross sections that were not possible with conventional perpendicular surfaces.
Solution Approach 2:
The invention introduces angular dimensions to the forming surfaces by slanting them at specific angles relative to the axial axis and relative to each other. This adds rotational and angular control dimensions to the forming process, allowing the glass to be deformed and distributed more precisely in three-dimensional space, resulting in sharper contours and better geometry definition.
2Manufacturing precision
If conventional forming tools are used, then the tool design is straightforward, but the glass distribution is incomplete and defects occur
Solution Approach 1:
Different forming surfaces are given different angular characteristics - the first forming surface is slanted at 5-15 degrees while the second forming surface is slanted at 60-85 degrees. This local differentiation in surface geometry allows specific regions of the glass to be controlled differently during forming, ensuring complete filling of the mold cavity and proper distribution of glass material without defects.
Solution Approach 2:
The slanted forming surfaces create curved flow paths for the glass material during the forming process. The angular surfaces guide the glass flow in a controlled manner, ensuring that the molten glass distributes evenly and completely fills the mold cavity, eliminating incomplete filling and defects associated with conventional perpendicular surfaces.
3Productivity
If high force is applied during forming, then the shaping speed is faster, but the glass geometry becomes distorted and produces defects
Solution Approach 1:
The slanted forming surfaces change the mechanical interaction between the tool and glass, distributing the forming force more evenly across the glass material. The angular geometry of the surfaces allows the glass to flow into the desired shape more naturally under reduced force, maintaining geometry accuracy while still achieving efficient forming speeds.
4Ease of manufacture
If conventional forming surfaces are used, then the tool is easier to manufacture, but the mold release is poor and requires additional drainage features
Solution Approach 1:
The slanted forming surfaces with specific angles (5-15 degrees and 60-85 degrees) provide inherent self-drainage characteristics. The angular geometry allows mold release agent to drain off naturally along the slanted surfaces without requiring additional drainage grooves or features, improving mold release efficiency while maintaining manufacturing simplicity.
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 tool enables the formation of precise geometries with thin cross sections, reduces defects and imbalances, and improves production efficiency by ensuring complete filling and better mold release, thereby minimizing rejects and tool wear.
Implementation Method 1
a part of the tool that contacts the heated portion comprises or is made of glassy carbon
Implementation Method 2
the moldable glass can be easily deformed and distributed within the form
Implementation Method 3
The forming takes place by way of outer forming dies that press the glass tube against the plug and simultaneously shape the outer side of the glass tube
Data Source
AI summary
Forming tool for glass forming in particular for forming bottle necks, with an axial central mounting section, provided with a flange, with forming surfaces on the flange where the forming surfaces are at an angle with a surface perpendicular to the axial axis of the mounting section, wherein the angle (X) is between 5-15 degrees, and with a second forming surface and two cutouts, wherein the forming surface and the cutout are at an angle (Y) when seen in the axial direction of 60-85 degrees.