Concentric Sleeve and Insert Tool for Molded Product Ejection

Solution Overview

Problem

Existing tools for forming moldable materials into desired shapes face challenges in easily releasing the formed products without causing damage or deformation, as they tend to stick to the mold, and air release systems are inefficient due to clogging and direct contact issues.

Innovation Solution

A tool comprising a sleeve and an insert with a concentrically mated design, where compressed air is directed through a gap between them to eject the formed product, minimizing contact and preventing deformation, and a wheel apparatus for high-volume manufacturing using multiple tools with air ejection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If air apertures are used in direct contact with the formed product for ejection, then the formed product can be ejected from the mold, but the air apertures become clogged with material and the high pressure air burst deforms or damages the formed product

Engineering Contradiction:

Improveejection of formed productVSAvoiddamage or deformation to formed product

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a air outlet tube as an intermediary component between the compressed air source and the formed product. The tube extends into the mold cavity and delivers air pressure to the formed product for ejection, while the air outlet is positioned to avoid direct contact with the product surface, preventing clogging and deformation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct mechanical contact ejection mechanisms (such as push rods or pistons that physically touch the product) with a pneumatic system using compressed air delivered through a tube, eliminating the need for mechanical components to contact the formed product

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If release agent is applied to the mold to prevent adhesion, then the formed product can be removed from the mold, but an undesirable residue is left on the formed product

Engineering Contradiction:

Improveremoval of formed productVSAvoidresidue on formed product

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the chemical release agent system with a mechanical/pneumatic ejection system. Compressed air delivered through a tube provides the force to eject the formed product from the mold without requiring release agents, thereby eliminating residue on the product surface

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If mechanical components are used to push or pull the formed product from the mold, then the formed product can be removed from the mold, but the mechanical components damage or deform the product

Engineering Contradiction:

Improveremoval of formed productVSAvoiddamage or deformation to formed product

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces direct mechanical contact ejection mechanisms (such as push rods or pistons that physically touch the product) with a pneumatic system using compressed air delivered through a tube, eliminating the need for mechanical components to contact the formed product

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a air outlet tube as an intermediary component between the compressed air source and the formed product. The tube extends into the mold cavity and delivers air pressure to the formed product for ejection, while the air outlet is positioned to avoid direct contact with the product surface, preventing clogging and deformation

Inventive Principle:

Principle #24Intermediary (Mediator)

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 easy and damage-free ejection of formed products by distributing air pressure uniformly, maintaining product integrity and facilitating high-volume production with efficient air release systems.

Implementation Method 1

An air passage in the insert connects an air inlet on the head of the insert to an air outlet on the surface of the barrel to direct compressed air to the air outlet. With the insert concentrically mated within the sleeve, a gap is defined between the insert and the sleeve, allowing compressed air exiting from the air outlet to flow through the gap and out the sleeve.

Methodology Applied

Scientific EffectCompressed air flow: Pressure Gradient

Implementation Method 2

With the product thus formed, a burst of compressed air is directed into the gap to eject the formed product from the tool.

Methodology Applied

Scientific EffectAir pressure ejection: Pressure Increase

Data Source

PatentUS7867418B2Tool and apparatus for forming a moldable material

Publication Date: 2011.01.11 MARS INC

AI summary

The present invention is directed to a tool and apparatus for forming a moldable material into a formed product having a desired shape, and optionally having a pouch for inserting pills, vitamins, and the like. The tool comprises a sleeve with a concentric insert, with a gap between the two for directing compressed air to eject the formed product from the tool. Exemplary apparatus using the tool and an associated method are also provided.