Annular Dose Formation Using Low-Pressure Cutting and Air Detachment
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Solution Overview
Problem
Existing methods for forming annular doses of plasticised material face issues such as material deterioration and adhesion to conduit surfaces due to high pressure, require low viscosity and high temperatures, and result in uncontrollable deformation and material runoff, especially when dealing with high or low viscosity materials.
Innovation Solution
A method and apparatus that separate an annular dose from a continuous flow of plasticised material using an extruder, where the material exits at relatively low pressure, with anti-adhesion treatments on the cutting element and air flow assistance to promote detachment and maintain material stability, allowing for processing at various viscosities and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure is used to press out the material, then the annular dose can be formed and separated, but the material temperature increases locally causing deterioration and adhesion to conduit surfaces
Solution Approach 1:
The patent extracts the harmful high-pressure pressing step from the process. Instead of using high pressure to force material through a mold, the system uses a cutting element to separate the annular dose from the continuous flow at low pressure, eliminating localized temperature increase and material deterioration
Solution Approach 2:
The patent replaces the mechanical high-pressure pressing system with a low-pressure cutting system. The cutting element mechanically separates the annular dose without requiring high pressure, thus avoiding the thermal and adhesion problems associated with high-pressure pressing
2Temperature
If low viscosity material is used, then processing can be performed at relatively low temperatures, but the material runs out from the seals
Solution Approach 1:
The patent removes the sealing constraint that causes material runoff. By using a cutting element to separate the annular dose rather than relying on seals to contain the material, the system can process low viscosity materials at low temperatures without material running out from seals
3Manufacturing precision
If high closing speed of mold is used, then the annular dose can be separated from continuous flow, but the material spurts out at high speed causing uncontrollable deformation
Solution Approach 1:
The patent replaces the high-speed mold closing system with a low-speed cutting system. The cutting element separates the annular dose from the continuous flow at low speed, preventing high-speed spitting and uncontrollable deformation while maintaining accurate dose shape
Solution Approach 2:
The cutting element acts as an intermediary between the continuous material flow and the formed annular dose. It provides a controlled separation mechanism that prevents direct high-speed ejection, allowing the dose to be formed and separated with controlled deformation
4Productivity
If high viscosity material is used, then operating speed can be increased, but very high operating speeds are required to maintain effectiveness
Solution Approach 1:
The patent creates a universal processing system that can effectively handle materials of various viscosities. The low-pressure cutting mechanism works equally well with high viscosity, low viscosity, and intermediate viscosity materials, eliminating the need for very high operating speeds required by high viscosity materials in traditional systems
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 annular doses with improved accuracy and repeatability, avoiding material deterioration and adhesion issues, and effectively processing both high and low viscosity materials at lower temperatures, reducing material runoff and deformation problems.
Implementation Method 1
The detachment of the dose from the cutting element may be promoted by a flow of air
Implementation Method 2
The surface of the cutting element may be provided with anti-adhesion means, for example the surface may be previously subjected to an anti-adhesion treatment to form an anti-adhesion surface layer
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method and an apparatus for forming annular doses (D) are disclosed wherein a flow of plasticised material supplied by an extruder passes through a channel (2) that is first cylindrical and then annular and exits from an annular outlet (3) in front of which a cutting element (8) passes that separates an annular dose of material that is deposited on a surface (S) of a capsule having a capacity to adhere to the dose that is greater than the cutting element; the surface and the cutting element are distanced from one another in such a manner that the annular dose, remaining adhering to the capsule, is detached from the element; detachment can be promoted by a flow of air.