Cylindrical Mould Member Thermal Welding
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Solution Overview
Problem
Existing methods for producing cylindrical mould members from porous and non-porous plastics lack a satisfactory connection between the mould body and support member, leading to structural weaknesses and reliability issues under the forces applied during the moulding process.
Innovation Solution
A method involving heat-emitting parts or particles near the inner surface of the mould body and support member, where energy is provided to cause local melting and welding of the plastics, creating a strong connection between the mould body and support member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical connections (bolts or other attachment means) are used to secure the support member and mould body, then the connection is simple to implement, but the connection strength is insufficient to withstand forces of thousands of kilos during moulding
Solution Approach 1:
The patent replaces mechanical connection systems (bolts, attachment means) with a thermal welding system. Heat-emitting parts or particles are used to locally melt and fuse the plastic support member and mould body together, creating a monolithic welded joint that eliminates the need for mechanical fasteners while providing sufficient strength to withstand moulding forces of thousands of kilos.
Solution Approach 2:
The patent changes the physical state of the plastic materials from solid to molten and back to solid through controlled local heating. By temporarily changing the temperature parameter of the plastic at the interface between support member and mould body, the materials become fusible, allowing them to merge into a single welded structure that provides superior connection strength.
2Strength
If the entire mould member is heated to weld the support member and mould body, then a strong weld is achieved, but excessive energy is consumed and the entire structure is affected by heat
Solution Approach 1:
The patent applies heating locally only at the interface between the support member and mould body where the weld is needed, rather than heating the entire mould member. Heat-emitting parts or particles are positioned specifically at this interface to melt and fuse the plastics locally, achieving strong weld strength while minimizing energy consumption and avoiding unwanted thermal effects on other parts of the structure.
Solution Approach 2:
The heating process is segmented into localized zones using discrete heat-emitting parts or particles positioned at the weld interface. This segmentation allows independent control of heat application at specific locations, enabling strong localized welding without the need to heat the entire mould member, thereby reducing overall energy consumption.
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 solution provides a robust weld that can withstand significant forces, ensuring reliable support and repeated use in moulding three-dimensional food products, with the weld being localized to minimize energy consumption and maintain structural integrity.
Implementation Method 1
providing energy to the heat emitting parts or particles, thereby causing the parts or particles to emit heat and thereby locally melt the adjacent porous first plastic and the second plastic to obtain a weld
Implementation Method 2
Heat transfer from the heat emitting parts or particles to the first and second plastic occurs via conduction: the transfer of thermal energy through materials without bulk motion of the materials
Implementation Method 3
Energy can be provided to the heat emitting parts or particles by allowing electrical current to pass through the heat emitting parts or particles
Implementation Method 4
Energy is provided to the heat emitting parts or particles by allowing Eddy currents to pass through the heat emitting parts or particles, thereby causing induction heating
Implementation Method 5
a heat emitting tube is provided close to the inner surface of the mould body and/or the supporting surface of the support member, through which a heated fluid is allowed to flow, causing the porous first plastic and the second plastic to locally melt
Data Source
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AI summary
The present invention relates to a rotary cylindrical mould member (20) and a method for its production, which is adapted to be used in a system for moulding three-dimensional products from a mass of one or more food starting materials which are suitable for consumption. The method comprising the steps of: preparing at least one mould body (22) forming part of the cylindrical outer surface (22c) of the mould member, wherein one or more recessed mould cavities (21) are formed. Subsequently preparing a support member (23) defining one or more fluid channels (24), recessed in the support surface (23a) Heat emitting parts or particles (28) are provided close to the inner surface (22i) of the mould body and/or the supporting surface of the support member. Energy is provided to the heat emitting parts or particles, thereby causing the parts or particles to emit heat and thereby locally melt the adjacent porous first plastic and the second plastic to obtain a weld and thereby secure the support member and the mould body to each other.