Compression Molding Closure Shells With In-Machine Disk Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing compression molding machines require a post-molding operation to remove a disk from the base wall of closure shells to create an opening, which is inefficient and adds extra steps to the manufacturing process.
Innovation Solution
A compression molding machine and method that uses a male and female mold section with an annular bead to compression mold a disk connected to the shell base wall by a thin frangible web, allowing the disk and shell to be stripped separately within the machine, eliminating the need for a post-molding operation to create the opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a disk is molded into the base wall and removed in a post-molding operation, then the opening is created in the shell base wall, but an additional post-molding operation is required which reduces productivity
Solution Approach 1:
The patent applies preliminary action by designing the mold to automatically remove the disk during the molding process itself. The male mold section includes a core that forms the disk, and the female mold section has a cavity that receives the disk after molding. This preliminary removal action eliminates the need for post-molding operations, thereby improving productivity while maintaining manufacturing precision.
Solution Approach 2:
The patent applies segmentation by separating the disk removal function from the shell molding function. The mold is designed with distinct male and female sections where the male section forms the shell with the disk, and the female section receives and retains the disk separately. This segmentation allows the disk to be automatically separated from the shell during the molding cycle, eliminating post-molding operations.
2Manufacturing precision
If a post-molding operation is used to remove the disk, then the opening is formed, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies merging by combining the disk removal function with the molding process itself. The mold design integrates the disk removal mechanism into the male and female mold sections, so that disk formation and removal occur during the same molding cycle. This merging eliminates the need for separate post-molding operations, reducing manufacturing process complexity.
3Productivity
If the disk is retained in the female mold cavity, then the disk and shell can be stripped separately, but the mold design becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the mold into male and female sections with distinct functions. The male section includes a core that forms the disk, and the female section has a cavity that receives and retains the disk. This segmentation allows the disk and shell to be stripped separately during the molding cycle, enabling in-machine disk removal while maintaining a relatively simple mold structure.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A compression molding machine, for compression molding a closure shell (128) having a base wall with an opening, includes a male mold section (54) and a female mold section (56) having associated surfaces that oppose each other to form a cavity for compression molding the base wall of the closure shell . An annular bead ( 114) on one of these surfaces cooperates with the opposing other surface to compression mold a disk connected to the base wall by a thin frangible web. The disk and the shell are stripped separately from the mold so that the shell emerges from the machine with the opening formed in the shell base wall by removal of the disk within the machine.