Concave Object Moulding Transition Zone Positioning
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Solution Overview
Problem
Existing compression moulding machines face issues with the precise positioning and uniform filling of polymeric material doses in the forming cavity, leading to defects and inefficiencies due to the dose's size and shape, which can result in off-center placement and prolonged positioning times.
Innovation Solution
The method involves placing the pre-processed element on a transition zone within the forming cavity, which is funnel-shaped, allowing for improved stability and precision in positioning by guiding the element towards the bottom, reducing the risk of off-center placement and premature contact with the cavity bottom, and facilitating faster introduction and shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dose has transversal dimensions only slightly smaller than the diameter of the forming cavity, then the productivity is improved by using a smaller forming cavity, but the manufacturing precision deteriorates due to non-centered positioning and non-uniform filling
Solution Approach 1:
A transport element is introduced as an intermediary device that carries the dose to the forming cavity. The transport element includes a transport surface that receives the dose and positions it precisely at the opening of the forming cavity, preventing off-center placement and ensuring uniform filling while maintaining high productivity
Solution Approach 2:
The dose is preliminarily positioned on the transport surface before being transferred to the forming cavity. This preliminary positioning ensures the dose is correctly oriented and located, preventing positioning errors during the actual forming process and enabling consistent high-precision production
2Quantity of substance
If the dose has considerable height, then the volume of polymeric material is increased, but the time required for positioning deteriorates as the dose needs longer to reach the bottom of the forming cavity
Solution Approach 1:
The transport element acts as a mediator that enables rapid transfer of the dose to the forming cavity. The transport surface is positioned to deliver the dose directly to the cavity opening, eliminating the time delay associated with the dose falling or moving to reach the bottom, thus reducing positioning time while maintaining adequate dose volume
3Device complexity
If the dose is placed directly in the forming cavity without a transport element, then the device complexity is reduced, but the manufacturing precision deteriorates due to off-center placement and non-uniform filling defects
Solution Approach 1:
The transport element is designed to perform multiple functions: it transports the dose, positions it precisely at the cavity opening, orients it correctly, and controls its release. This multi-functionality achieves high filling uniformity without requiring multiple separate devices, thus maintaining relatively simple device complexity while dramatically improving manufacturing precision
Data Source
AI summary
A method comprises the following steps:providing a pre-processed element made of at least one polymeric material,introducing the pre-processed element in a female mould part having a forming cavity,shaping the pre-processed element between the female mould part and a male mould part, the female mould part and the male mould part being movable relative to one another along a moulding direction so as to form a concave object from the pre-processed element.The forming cavity has a transversal dimension measured transversely relative to the moulding direction, the forming cavity further having a transition zone in which the transversal dimension passes from a larger value to a smaller value, the forming cavity further having a bottom.During the introducing step, the pre-processed element is placed on the transition zone, so that the pre-processed element rests on the transition zone at a distance from the bottom of the forming cavity.