Continuous Blow Molding with Movable Chambers and IR Heating
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Solution Overview
Problem
Existing blow molding devices are not suitable for continuous processing as the heating unit and molding unit are integrally fixed, requiring significant time to open and close the support unit for loading and ejecting materials.
Innovation Solution
A blow molding device configuration with movable chambers allows for continuous processing by heating the material, applying gas pressure to one side, and using negative pressure on the other side to shape the material without opening or closing the sealed space, enabling automated loading and ejecting of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the heating unit and molding unit are integrally fixed, then the structural stability is improved, but the productivity deteriorates due to required opening and closing operations
Solution Approach 1:
The device is divided into a fixed heating unit and a movable molding unit (chamber assembly). The molding unit can be moved between a processing position (under the heating unit) and an ejector position (removed from under the heating unit), allowing continuous operation without requiring the entire device to be opened or closed.
2Ease of operation
If the support unit is opened and closed for loading and ejecting materials, then the ease of operation is improved, but the loss of time increases
Solution Approach 1:
The molding chamber is designed as a movable unit that can be dynamically repositioned. The chamber is removed from under the heating unit after processing and replaced with a new chamber for the next material, enabling continuous operation without time-consuming opening and closing of a fixed support unit.
3Manufacturing precision
If the molding material is heated and shaped in a sealed space, then the manufacturing precision is improved, but the productivity deteriorates due to workflow interruption
Solution Approach 1:
Multiple molding chambers are prepared in advance. While one chamber is being used for processing (maintaining sealed space for precision), other chambers are pre-positioned and ready for immediate use, allowing seamless transition without workflow interruption.
Solution Approach 2:
The system maintains continuous processing by having the movable chamber assembly cycle between processing and ejection positions. The heating unit continuously processes materials in the chamber while positioned underneath, and the chamber is quickly replaced after ejection, eliminating idle time and maintaining continuous useful action.
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 continuous blow molding of multiple materials by allowing simultaneous heating, shaping, and ejection processes without interrupting the workflow, improving efficiency and reducing operational time.
Implementation Method 1
an infrared lamp configured to emit infrared rays... the infrared rays emitted from the infrared lamp are concentrated on an upper surface of the quartz rod... the molding material S placed on the molding unit 160 is heated by the infrared rays
Implementation Method 2
a reflective mirror configured to concentrate the infrared rays emitted from the infrared lamp... the infrared rays emitted from the infrared lamp are concentrated on an upper surface of the quartz rod 124 disposed below the reflective mirror 121
Implementation Method 3
a light transmitting body configured to transmit the infrared rays concentrated by the reflective mirror to the molding material... the quartz rod 124 functions as a light transmitting body for transmitting infrared rays
Implementation Method 4
molds between which the molding material is loaded and molded... the molds mold the molding material by using gas pressures applied to surfaces of the molding material
Implementation Method 5
the blow molding is performed by rapidly raising, by using the heating unit 120, a temperature of the lower surface of the quartz rod 124 up to a predetermined target temperature, and then injecting a gas into a pressurized gas injection port
Data Source
AI summary
The present invention relates to a blow molding device including: a heating unit which is configured to heat a molding material; and molds between which the molding material is loaded and molded, in which the heating unit includes: an infrared lamp configured to emit infrared rays, a reflective mirror configured to concentrate the infrared rays emitted from the infrared lamp; and a light transmitting body configured to transmit the infrared rays concentrated by the reflective mirror to the molding material, and in which the molds mold the molding material by using gas pressures applied to surfaces of the molding material heated to a predetermined temperature by the infrared rays transmitted from the light transmitting body.