Continuous Stretch-Blow-Moulding Machine for Non-Symmetric Preforms
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Solution Overview
Problem
The existing stretch-blow-moulding process for polymer containers with integral handles is inefficient due to the complexity of handling non-symmetric preforms, requiring precise orientation and preheating while protecting the handle from excessive heat, and involves discontinuous batch processing which is less efficient than a continuous feed system.
Innovation Solution
A continuous non-symmetric preform feed stretch-blow-moulding machine with a preform orientation system that maintains handle orientation throughout the process, utilizing a pick and place apparatus with cam followers for precise handling and a heat shield to prevent heat absorption, enabling continuous transfer and preheating of preforms with integral handles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous feed system is used for stretch-blow-moulding, then productivity increases, but device complexity increases due to the need for rotating transfer systems and continuous orientation maintenance
Solution Approach 1:
The patent implements a continuous feed system where preforms are constantly fed through the moulding process without batch interruptions. The rotating in-feed wheel, preheating stage, and moulding units operate continuously, with preforms being transferred from one station to the next in an unbroken sequence, maximizing productivity while maintaining continuous material flow through the system.
Solution Approach 2:
The continuous feed system is divided into distinct functional segments: an in-feed wheel for preform supply, a preheating stage for temperature control, multiple moulding units for forming, and an outfeed section for finished product removal. Each segment operates independently but coordinates through the continuous rotation, allowing complex functionality to be managed through modular organization.
2Manufacturing precision
If precise handle orientation is maintained throughout the process, then manufacturing precision improves, but device complexity increases due to orientation control mechanisms
Solution Approach 1:
The in-feed wheel is designed with preform holders that establish the correct handle orientation before the preform enters the moulding process. The preforms are inserted into the rotating wheel with their handles aligned to specific positions, and this predetermined orientation is maintained throughout the subsequent processing stages through the coordinated rotation of transfer mechanisms.
Solution Approach 2:
The orientation control system uses dynamic rotation of the in-feed wheel and transfer mechanisms to maintain precise handle alignment. As the wheel rotates and preforms are transferred between stations, the system dynamically adjusts positions and angles to ensure handles remain correctly oriented relative to the moulding cavities, achieving high precision through motion control rather than static positioning.
3Reliability
If the handle is protected from excessive heat during preheating, then reliability improves, but device complexity increases due to heat shield requirements
Solution Approach 1:
Heat shields are positioned specifically around the handle regions of the preforms during the preheating stage, providing localized thermal protection only where needed. The shields are strategically placed to block heat from reaching the handles while allowing the body portions of the preforms to reach the required processing temperatures, protecting sensitive areas without compromising the overall heating process.
4Ease of operation
If batch processing is used for handling non-symmetric preforms, then ease of operation improves, but productivity decreases due to incremental processing pauses
Solution Approach 1:
The system eliminates batch processing interruptions by implementing continuous rotation of the in-feed wheel and continuous movement of preforms through the preheating and moulding stages. The process flows without pauses, with each station operating continuously and transferring workpieces in an unbroken sequence, thereby maximizing production rate while maintaining operational simplicity through automated continuous motion.
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 allows for the efficient and continuous production of stretch-blow-moulded containers with integral handles by ensuring precise orientation and controlled preheating, enhancing production efficiency and reducing material costs through optimized polymer distribution and reduced material volume.
Implementation Method 1
a preheating process is applied before preforms enter the blow mould die
Implementation Method 2
correct preheating of the preform while protecting the handle from excessive heat absorption
Data Source
AI summary
A continuous non-symmetric preform feed stretch-blow-moulding machine dedicated to the stretch-blow-moulding of containers from non-symmetric injection moulded preforms; the non-symmetrical preforms including an integral handle extending from a first junction point to a second junction point on a body of the preform; the body of the preform and the integral handle constituted from the same material.