Batch-Specific Cure Timing for Molded and Extruded Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing processes for curing raw materials in molds are inefficient, leading to prolonged curing times and reduced productivity due to the need for materials to remain in the mold longer than necessary, especially for larger parts.
Innovation Solution
A method and system that determine the cure properties of raw material batches, allowing for optimized curing times based on batch-specific properties, enabling parts to be removed from the mold when a desired degree of curing is achieved, and using a database to store and retrieve these properties for automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the raw material remains in the mold longer than necessary for curing, then the required curing is reliably achieved, but the productivity of the manufacturing process is reduced
Solution Approach 1:
The patent applies parameter changes by determining specific cure properties (such as curing speed, crosslinking rate, or gel time) for each batch of raw material and using these measured parameters to calculate optimized curing times. This replaces the conventional fixed curing time approach with a dynamic, parameter-based curing time determination, allowing the process to adapt to batch-specific material variations and achieve reliable curing with minimal mold residence time.
Solution Approach 2:
The patent implements feedback by measuring cure properties of raw material batches and using this information to adjust and optimize curing times. The system continuously monitors material characteristics and feeds this information back into the process control, enabling real-time optimization of curing parameters to balance curing reliability with productivity improvement.
2Productivity
If the cure properties are determined for each batch of raw material, then the curing time can be optimized and productivity improved, but the initial effort and measurement requirements increase
Solution Approach 1:
The patent applies self-service by enabling the raw material batches to 'self-characterize' through automated cure property measurements. The system uses automated testing equipment to determine cure properties directly from the material, eliminating the need for complex manual characterization processes. This self-service approach simplifies the overall complexity by allowing the material to provide its own parameters for optimization.
Solution Approach 2:
The patent implements preliminary action by determining cure properties of raw material batches in advance, before the actual molding process. By performing these measurements and calculations beforehand, the system prepares optimized curing times that can be directly applied during production, avoiding the need for complex real-time adjustments and reducing operational complexity.
3Ease of operation
If the raw material is cured for a fixed time regardless of batch properties, then the process is simple to operate, but the curing time cannot be optimized and productivity is reduced
Solution Approach 1:
The patent applies copying by creating a database of cure properties from representative samples or previous batch data, which can be copied and applied to similar material batches. This allows the system to maintain simplicity by using pre-determined cure parameters from a library, rather than requiring complex real-time measurements for every batch, thus balancing ease of operation with productivity optimization.
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
Significantly reduces curing time and improves overall productivity by up to 30% while maintaining product quality, despite the initial effort required for determining cure properties, and allows for automated and traceable production processes.
Implementation Method 1
The raw material is a material that can be cured by crosslinking. The raw material cures due to a chemical reaction.
Data Source
AI summary
The present invention refers to a method to produce parts by shaping and curing a raw material comprising the steps:a batch of raw material is produced;at least one cure property of the raw material of the sample is determined;shaping the raw material;the time required for the shaped raw material to cure is determined taking into account the at least one cure property;curing of the shaped raw material until the determined time has elapsed.The present invention also refers to a database and a system for producing such parts.