Continuous Blow Moulding Machine for Plastic Bottles
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Solution Overview
Problem
Existing blow moulding technologies for manufacturing plastic bottles from semi-rigid plastic sheets face limitations in throughput, reliability, and cost, particularly when producing volumes greater than 500 ml, and struggle with managing varying plastic thicknesses and ergonomic maintenance access.
Innovation Solution
A machine design that includes a roll of plastic material, a shaper for forming tubes, longitudinal welding, transverse cutting, and an oven for preforms, with synchronized turrets for processing and blowing, utilizing continuous ultrasound welding and radiant heat for efficient and high-throughput production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cyclical in-line blow moulding machines are used, then plastic bottles can be manufactured free of defects, but throughput is limited and cost is significant
Solution Approach 1:
The patent implements continuous linear motion of the plastic strip through the manufacturing process, replacing the cyclical reciprocating motion of traditional machines. The strip moves continuously through shaping, welding, cutting, and blow moulding stations, eliminating idle time and cycle transitions, thereby significantly increasing throughput while maintaining defect-free production
2Ease of manufacture
If traditional cyclical machines are used, then manufacturing can be performed, but mechanical breakdowns and wear are frequent
Solution Approach 1:
The patent replaces the complex reciprocating mechanical drive system with a simpler continuous linear transport mechanism. The plastic strip is conveyed continuously through fixed tooling stations rather than being repeatedly accelerated, decelerated, and repositioned, reducing mechanical stress, wear, and breakdown frequency while maintaining manufacturing capability
3Temperature
If oven access is not ergonomic, then heating can be performed, but maintenance access is difficult
Solution Approach 1:
Instead of making the oven move with the plastic strip, the patent inverts the approach by keeping the oven stationary and moving the plastic strip continuously through it. This allows the oven to be fixed in an easily accessible location for maintenance while still performing its heating function on the moving strip
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
The machine achieves high throughput rates of 20,000 to 30,000 bottles per hour with improved reliability, reduced wear, and enhanced ergonomic maintenance access, while minimizing mechanical breakdowns and energy consumption.
Implementation Method 1
said welding means comprises at least one sonotrode arranged so as to perform continuous welding by longitudinal welds of said tubes
Implementation Method 2
said anvil has a profile arranged so as to concentrate the welding energy along a line
Implementation Method 3
at least one oven in which said tube sections (preforms) are moved in the vertical position along a horizontal trajectory
Data Source
AI summary
The invention concerns a machine for manufacturing plastic items comprising, in series, along the manufacturing line: a rotatable roll (1) of plastic material in the form of at least one strip; a shaper (4) for forming tubes from said strips and means (5) for longitudinally welding said tubes; means (6) for cutting the tubes transversely, arranged so as to form tube sections (10); means for transferring and depositing said sections in holding and moving means; an oven (8) in which said tube sections move; a first turret (9) supporting moulds; means for processing the tube sections in the first turret; means for blowing a pressurised fluid into the moulds; a second turret (14) for discharging the bottles from said moulds.