Angled Bottle-Neck Forming Tool for Precise Glass Filling
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Solution Overview
Problem
Existing glass forming tools are inadequate for producing high-precision geometries required for medical containers, particularly in forming vial necks, as they limit the achievable geometries and result in incomplete filling, defects, and require excessive force, leading to rejects and tool wear.
Innovation Solution
A forming tool with slanted rotated forming surfaces at specific angles (5-15 degrees for X and 60-85 degrees for Y) and cutouts, which facilitate even glass distribution and reduce contact force, allowing for precise, complete filling of complex geometries without additional drainage needs.
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 glass cannot be evenly distributed leading to incomplete filling and defects
Solution Approach 1:
The patent applies parameter changes by modifying the forming surfaces from perpendicular to the axis to slanted at specific angles (5-15 degrees for surface X and 60-85 degrees for surface Y relative to cutouts). This angular parameter change enables even glass distribution and complete filling of the mold cavity, achieving precise thin-walled geometries without increasing overall tool complexity
Solution Approach 2:
The patent introduces asymmetry through the slanted forming surfaces at specific angles rather than symmetric perpendicular surfaces. The asymmetric angle configuration (5-15 degrees and 60-85 degrees) creates optimized material flow patterns that enable complete filling and even glass distribution, improving manufacturing precision for complex geometries
2Duration of action of stationary object
If conventional forming tools are used, then the tool design is simple, but excessive force is required leading to high tool wear and reduced longevity
Solution Approach 1:
The patent reduces forming force by changing the surface angle parameters from perpendicular to slanted configurations. The specific angles (5-15 degrees and 60-85 degrees) optimize the force distribution during forming, reducing peak forces and preventing glass accumulation, which directly decreases tool wear and extends tool longevity
3Manufacturing precision
If conventional forming tools are used, then the tool structure is simple, but defects and imbalances occur requiring additional drainage features
Solution Approach 1:
The patent eliminates the need for additional drainage features by optimizing the forming surface angles. The slanted surfaces at 5-15 degrees and 60-85 degrees naturally guide glass flow and prevent accumulation, achieving uniform glass distribution and complete filling without requiring extra drainage grooves or features, thus maintaining simple tool structure while improving precision
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
Enables the formation of precise, thin-walled geometries with reduced defects and rejects, improved tool longevity, and gentler shaping, eliminating the need for additional drainage features and reducing machine downtime.
Implementation Method 1
a part of the tool that contacts the heated portion comprises or is made of glassy carbon
Implementation Method 2
a portion of the intermediate glass product is heated to a predetermined temperature
Data Source
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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 (63) and two cutouts (155), wherein the forming surface (63) and the cutout (155) are at an angle (Y) when seen in the axial direction of 60-85 degrees.