Blow Molding Tool Insulation Blocks Reduce Energy

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Solution Overview

Problem

The high energy expenditure and prolonged cycle times in blow molding processes due to the need for continuous heating and cooling of blow molding tools, which are often not economically viable, especially when trying to maintain optimal temperature conditions for plastic container production.

Innovation Solution

A blow molding tool design featuring thermally insulating blocks between the molding body and baseplate, with polished shaping surfaces and embedded heating/cooling channels, allowing for rapid interval cooling and reduced energy consumption, enabling the production of glossy and structured plastic container surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If continuous heating and cooling of blow molding tools is implemented, then optimal temperature conditions for plastic container production are maintained, but energy expenditure increases and cycle times are prolonged

Engineering Contradiction:

Improvetemperature conditionsVSAvoidenergy expenditure

Core Design Contradiction:

TemperatureVSUse of energy by stationary object

Solution Approach 1:

The blow molding tool is divided into thermally isolated segments using insulation blocks between the molding body and baseplate. This segmentation allows independent thermal management of different tool components, enabling localized heating and cooling only where necessary, thus reducing overall energy consumption while maintaining optimal temperatures at the mold cavity surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements periodic interval cooling instead of continuous cooling. The cooling medium is supplied intermittently through channels in the baseplate during specific phases of the blow molding cycle, allowing the tool to retain heat during shaping operations while removing excess heat during demolding phases. This periodic approach significantly reduces energy expenditure compared to continuous cooling.

Inventive Principle:

Principle #19Periodic action

2Temperature

If continuous heating and cooling of blow molding tools is implemented, then optimal temperature conditions for plastic container production are maintained, but cycle times are prolonged

Engineering Contradiction:

Improvetemperature conditionsVSAvoidcycle times

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The cooling system operates periodically rather than continuously, with cooling medium supplied only during necessary phases of the blow molding cycle. This interval cooling approach reduces the time required for thermal management operations, thereby shortening overall cycle times and improving productivity while still achieving optimal temperature conditions for container production.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Thermal management is applied locally at specific regions of the blow molding tool rather than uniformly across the entire tool. Insulation blocks create zones with different thermal characteristics, allowing rapid cooling at the mold cavity surface while maintaining higher temperatures in other areas. This localized approach reduces the total time required for thermal processing.

Inventive Principle:

Principle #3Local quality

3Use of energy by stationary object

If thermally insulating blocks are introduced, then thermal bridges are minimized and energy expenditure is reduced, but device complexity increases

Engineering Contradiction:

Improveenergy expenditureVSAvoiddevice complexity

Core Design Contradiction:

Use of energy by stationary objectVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

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

This design reduces energy expenditure and cycle times, allowing for the production of high-quality plastic containers with glossy and structured surfaces, previously difficult to achieve with polyolefins, while minimizing thermal bridges and maintaining precise mold cavity reproduction.

Implementation Method 1

An insulation block (16) consisting of a thermally insulating material is arranged between the molding body (5) and the baseplate (4)

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

embedded heating/cooling channels, allowing for rapid interval cooling

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12064915B2Blow molding tool for a blow molding machine

Publication Date: 2024.08.20 ALPLA WERKE ALWIN LEHNER

AI summary

The invention relates to a blow molding tool for a blow molding machine for producing plastic containers in an extrusion or stretch blow-molding process. The blow molding tool comprises two blow mold halves, each of which comprises at least one molding body in which at least one mold cavity is disposed, and a baseplate that receives said molding body. An insulation block consisting of a thermally insulating material is arranged between the molding body and the baseplate and, optionally, further components of the blow mold halves.