Ball Screw Punching Device for High-Speed Plastic Container Separation

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Solution Overview

Problem

Existing separating devices for plastic container products from frame assemblages are inefficient, particularly with polypropylene, requiring long waiting times and additional cooling due to the material's brittleness, and are costly, especially when using multilayer systems.

Innovation Solution

A separating device utilizing a ball screw driven by an electric motor to move the punching device along a punching axis, allowing for high-speed separation without additional cooling or maintenance of cutting edges, and incorporating a damping system to prevent overloading and extend the ball screw's service life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional punching devices are used to separate polypropylene container products from frame assemblages, then separation can be achieved, but long waiting times and additional cooling are required due to the material's brittleness

Engineering Contradiction:

Improveseparation qualityVSAvoidwaiting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent changes the operational parameters of the punching device by using a reciprocating motion with controlled speed and acceleration. The punching device moves at a speed of 0.1-10 m/s and applies force during a specific stroke portion, allowing separation of brittle polypropylene without requiring additional cooling or long waiting times. This parameter optimization resolves the contradiction between separation quality and production time.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If multilayer systems are used to prevent gas diffusion into container contents, then barrier protection is improved, but production costs increase significantly

Engineering Contradiction:

Improvegas diffusion protectionVSAvoidproduction cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent employs a cost-effective single-layer polypropylene container design with optimized separation methodology rather than expensive multilayer systems. The high-quality reciprocating punching separation ensures clean detachment of containers from the frame assemblage without requiring complex multilayer constructions, thereby reducing production costs while maintaining functional integrity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If higher processing temperatures are used to improve sterility, then sterile conditions are enhanced, but temperature-sensitive plastic materials cannot be processed

Engineering Contradiction:

ImprovesterilityVSAvoidmaterial compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent segments the processing into distinct functional zones: a sterile processing zone for container formation and filling, and a separate separation zone for punching. This allows the container to be formed and filled under sterile conditions at appropriate temperatures, then separated using a controlled reciprocating punching mechanism that does not require high temperatures, thus protecting temperature-sensitive materials while maintaining sterility where needed.

Inventive Principle:

Principle #1Segmentation

4Productivity

If conventional cutting devices are used for separation, then container products can be detached from frame waste, but cutting edges require reworking and maintenance

Engineering Contradiction:

Improveseparation speedVSAvoidcutting edge maintenance

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The patent replaces the conventional continuous-contact cutting mechanism with a reciprocating punching system that uses impact force rather than friction-based cutting. The punching device with reciprocating motion delivers controlled blows to separate containers from the frame assemblage, eliminating the need for continuously sharpened cutting edges and reducing maintenance requirements while maintaining high separation speed.

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

Enables clean, high-speed separation of polypropylene container products from frame waste with reduced energy usage and lower production costs, applicable to various plastic materials including polypropylene and multilayer systems, without the need for reworking cutting edges or additional cooling.

Implementation Method 1

a ball screw (46) which can be actuated by an electric motor (48) is used to move the punching device (36) from an initial position into the punching position along a punching axis (44) and vice versa

Methodology Applied

Scientific EffectBall screw mechanism: Screw

Implementation Method 2

a damping system (72) is used which prevents overloading of the ball screw (46) in the punching process

Methodology Applied

Scientific EffectDamping: Damping

Data Source

PatentUS8578828B2Separating device

Publication Date: 2013.11.12 HANSEN BERND

AI summary

A separating device for cutting off individual containers (12) from a frame network made of a plastic material, particularly of polypropylene, has at least one punching device at least partially separating the containers (12) from a waste frame. Because the punching device can be moved by a ball screw drive (46) that can be driven by a drive unit, particularly in the form of an eclectic motor (48), along a punching axis (44) from a starting position to a punching position and back again, the separation can be done at high speed, determined by the screw shaft that can be driven by the electric motor.