Continuous Mold Segment Apparatus for Space-Efficient Container Fabrication

Solution Overview

Problem

Existing container fabrication processes require significant floor space and energy consumption due to the need for separate machinery for filling and transporting containers, as well as clamping mold segments together during the molding process, which limits production efficiency and increases operational complexity.

Innovation Solution

A container fabrication apparatus featuring a closed path guiding mechanism for mold segments, where each segment is configured to form a mold cavity with another, allowing for continuous production of filled containers with a single apparatus, reducing the need for additional filling and transport machinery and minimizing energy consumption by using pressure within the mold cavities to maintain mold segment alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If separate machinery for filling and transporting containers is used, then the container fabrication process can be completed, but the floor space required and energy consumption increase significantly

Engineering Contradiction:

Improvecontainer fabrication capabilityVSAvoidfloor space

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The patent combines the container forming process and filling process into a single integrated apparatus. The mold segments are designed to contain both the forming cavity and the filling mechanism, allowing containers to be formed and filled continuously without transfer to separate machinery, thereby reducing floor space while maintaining productivity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mold segments serve multiple functions: they form the container shape, contain the preform during blowing, and provide the filling mechanism. This multi-functionality eliminates the need for separate filling and transporting machinery, reducing overall floor space requirements while maintaining continuous production capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If clamping mechanisms are used to hold mold segments together during molding, then mold segment alignment is maintained, but energy consumption and device complexity increase

Engineering Contradiction:

Improvemold segment alignmentVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by stationary object

Solution Approach 1:

The mold segments are designed to self-align and self-lock through their own structural features during the molding process. The segments utilize the pressure differential created during preform blowing to maintain alignment without requiring external clamping mechanisms, thereby reducing energy consumption while maintaining manufacturing precision

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent removes the clamping mechanism from the system entirely, relying instead on the inherent structural design of the mold segments and the process physics to maintain alignment. This extraction of the clamping function eliminates the energy consumption and complexity associated with separate alignment maintenance mechanisms

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If clamping mechanisms are used to hold mold segments together during molding, then mold segment alignment is maintained, but device complexity increases

Engineering Contradiction:

Improvemold segment alignmentVSAvoidoperational complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent removes the clamping mechanism from the system entirely, relying instead on the inherent structural design of the mold segments and the process physics to maintain alignment. This extraction of the clamping function eliminates the energy consumption and complexity associated with separate alignment maintenance mechanisms

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mold segments are designed to self-align and self-lock through their own structural features during the molding process. The segments utilize the pressure differential created during preform blowing to maintain alignment without requiring external clamping mechanisms, thereby reducing energy consumption while maintaining manufacturing precision

Inventive Principle:

Principle #25Self-service

4Productivity

If multiple separate apparatuses are used for forming and filling, then process specialization is achieved, but operational complexity and energy consumption increase

Engineering Contradiction:

Improvecontinuous production capabilityVSAvoidnumber of apparatuses

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines the container forming process and filling process into a single integrated apparatus. The mold segments are designed to contain both the forming cavity and the filling mechanism, allowing containers to be formed and filled continuously without transfer to separate machinery, thereby reducing floor space while maintaining productivity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mold segments serve multiple functions: they form the container shape, contain the preform during blowing, and provide the filling mechanism. This multi-functionality eliminates the need for separate filling and transporting machinery, reducing overall floor space requirements while maintaining continuous production capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 apparatus achieves space-efficient and energy-saving container production by integrating filling and forming processes, reducing the complexity of operations, and improving container quality by eliminating mold separation lines, while maintaining high production rates and quality.

Implementation Method 1

a blank parison or 'preform' is positioned within the cavity of a mold and injected with a pressurized gas, usually air, causing it to inflate and assume the contours of the mold cavity

Methodology Applied

Scientific EffectGas pressure: Pressure Increase

Implementation Method 2

the stretch blow molding process, wherein the preform is mechanically stretched along a longitudinal axis while being inflated

Methodology Applied

Scientific EffectMechanical stretching: Deformation

Implementation Method 3

injecting a liquid at a pressure sufficient to cause expansion of the preform into the contours of the mold cavity

Methodology Applied

Scientific EffectPressure injection: Pressure Increase

Data Source

PatentUS10300652B2Method for fabricating containers

Publication Date: 2019.05.28 DISCMA AG

AI summary

A method for fabricating containers wherein a molding apparatus is provided having a plurality of mold segments, each of which has two substantially opposite faces that form a mold cavity when abutted against an opposite face of an adjacent mold segment. A first mold segment is passed through a manipulation zone at an increased speed to open the mold cavity between the first and second mold segments. After a preform is positioned within the mold cavity, a second mold segment is passed through the manipulation zone at an increased speed to abut a face of the first mold segment against an opposite face of the second mold segment. A volume of a liquid is next injected into the preform, expanding the preform and forming the container. These steps are repeated and a container produced during the previous iteration is removed during an extracting step in an extracting manipulation zone.