Continuous Preform Transport in Injection Moulding

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Solution Overview

Problem

The existing methods for producing plastic material preforms in injection moulding cycles face limitations in integrating directly with continuous stretch blow-moulding processes, leading to material damage and quality issues due to the continuous operation of stretch blow-moulding machines.

Innovation Solution

An apparatus comprising multiple manufacturing devices connected to a continuous main transport device, which uses a circulating transport system like a transport chain or linear motor to convey plastic material preforms in a clocked manner, allowing for continuous production and reducing the need for subsequent heating, thus enhancing the integration with stretch blow-moulding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If plastic material preforms are produced in injection moulding cycles and stored for subsequent processing, then the production process is simple and reliable, but the continuous operation of stretch blow-moulding machines cannot be supported and material damage occurs

Engineering Contradiction:

Improveproduction process reliabilityVSAvoidcontinuous production capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements a continuous injection moulding process where preforms are produced and transferred continuously without interruption. The rotary injection moulding machine with multiple cavities produces preforms in a continuous sequence, and the transfer device continuously conveys them to the stretch blow-moulding machine, eliminating the discontinuous batch production of traditional injection moulding cycles and enabling continuous operation of the entire production line.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent introduces a transfer device as an intermediary between the injection moulding machine and the stretch blow-moulding machine. This transfer device includes transfer arms and transfer stations that continuously move preforms from the injection moulding machine to the stretch blow-moulding machine, solving the incompatibility between the two machines and enabling their direct connection for continuous production.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If plastic melt is applied to a rotary system for continuous injection moulding, then continuous production is achieved, but the material can be damaged and quality of preforms is impaired

Engineering Contradiction:

Improvecontinuous production capabilityVSAvoidpreform quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent divides the injection moulding process into multiple independent cavities (e.g., 8 cavities) arranged on the rotary machine. Each cavity independently produces preforms that are then individually transferred. This segmentation allows the continuous process to maintain quality control for each preform while achieving overall continuous production, reducing material damage compared to a single large continuous system.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If multiple manufacturing devices produce preforms in clocked mode, then production flexibility and quality control are improved, but integration with continuous stretch blow-moulding processes is limited

Engineering Contradiction:

Improvepreform production controlVSAvoidintegration with continuous processes

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent uses a rotary injection moulding machine with multiple cavities that rotates continuously, dynamically producing preforms in a sequence that matches the requirements of the stretch blow-moulding machine. The transfer device dynamically adjusts to transfer preforms at the correct timing and position, enabling the clocked production of multiple devices to integrate seamlessly with the continuous stretch blow-moulding process.

Inventive Principle:

Principle #15Dynamics

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

This solution enables the production of high-quality plastic material preforms that can be directly expanded into containers with improved energy efficiency and reduced costs by maintaining sterility and simplifying the system, eliminating the need for complex hot-runner technology and decontamination units.

Implementation Method 1

a circulating transport device in the form of a long stator linear motor can also be provided

Methodology Applied

Scientific EffectLinear motor: Linear Motor

Data Source

PatentUS11667056B2Injection moulding machine for continuous production

Publication Date: 2023.06.06 KRONES AG

AI summary

Apparatus for producing plastic material preforms, includes at least two preform manufacturing devices configured for producing the plastic material preforms from a plastic material, wherein the preform manufacturing devices each having preform transport devices. The apparatus includes a main transport device which is configured for transporting the plastic material preforms produced by the preform manufacturing devices and transported by the preform transport devices continuously along a predetermined main transport path, wherein the plastic material preforms are transferred to the main transport device by the production devices after their production.