Deep-Drawing Moulding Device Air Distribution
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Solution Overview
Problem
Existing molding devices for deep-drawing cups in heated film webs suffer from high air consumption and flow losses due to inefficient compressed air distribution and long transport paths, leading to suboptimal throughput.
Innovation Solution
A molding device with a first tool featuring a stamping element and pressure plate with a through-opening, and a second tool with a mold cavity, where a valve device in the stamping element acts as a compressed air reservoir, minimizing air transport distance and enabling quick refilling, and utilizing a valve assembly with a horizontal valve plate and spherical closing element for controlled air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compressed air is supplied via separate supply lines to each pre-stretching ram, then the cups can be formed with uniform wall thickness, but high flow losses occur leading to reduced throughput
Solution Approach 1:
The patent combines multiple separate air supply lines into a single common supply line that distributes compressed air to multiple pre-stretching rams simultaneously. This merging eliminates the high flow losses associated with multiple separate lines while maintaining the ability to form cups with uniform wall thickness, thereby improving throughput without sacrificing manufacturing precision.
Solution Approach 2:
The patent introduces a common air supply line as an intermediary component that acts as a distribution manifold. This intermediary efficiently distributes compressed air to multiple pre-stretching rams, reducing flow losses compared to individual supply lines while ensuring uniform air pressure and flow to each ram for consistent cup formation.
2Ease of operation
If a large number of pre-stretching rams are provided with separate supply lines, then each ram can be independently controlled, but air consumption increases and refilling time is extended
Solution Approach 1:
The patent merges multiple individual air supply lines into a single common supply line that serves all pre-stretching rams. This consolidation reduces overall air consumption by eliminating redundant piping and flow losses, while the system maintains independent control capability through individual valve devices at each ram location.
Solution Approach 2:
The common air supply line serves multiple functions simultaneously: it distributes compressed air to all pre-stretching rams, acts as a refilling reservoir, and provides pressure regulation. This multi-functional design reduces air consumption while maintaining operational flexibility and independent control of each ram.
3Speed
If separate supply lines are used for each pre-stretching ram, then air can be delivered directly to each ram, but dead volume increases causing large drops in compressed air pressure
Solution Approach 1:
The patent combines multiple separate supply lines into a single common supply line with significantly reduced total volume and dead space. This merging minimizes compressed air pressure drops by eliminating redundant piping while maintaining fast air delivery speed to all pre-stretching rams through efficient distribution.
4Manufacturing precision
If compressed air transport path is long, then air can reach all rams evenly, but flow losses increase and throughput decreases
Solution Approach 1:
The common air supply line acts as an intermediary distribution manifold that efficiently delivers compressed air to multiple pre-stretching rams with minimal transport distance. This intermediary design ensures even air distribution to all rams while minimizing flow losses and transport path length, thereby maintaining manufacturing precision without sacrificing throughput.
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 configuration reduces air consumption and flow losses, enhancing throughput by ensuring efficient and loss-free compressed air distribution, allowing for higher production rates with minimal maintenance requirements.
Implementation Method 1
The cavity formed in the plunger member functions as a compressed air reservoir for storing compressed air. Since this compressed air reservoir is in the immediate vicinity of the pre-stretching ram, the compressed air transport path to the pre-stretching ram is minimal.
Implementation Method 2
A valve device is in turn provided in the cavity for opening and closing the opening in the wall surface.
Data Source
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AI summary
The forming device (2) for deep drawing cups (4) in a heated film web (6) comprises a first forming tool (8) and a second forming tool (10). The first forming tool (8) comprises a punch element (18) with at least one projecting punch projection (30) and a pressure plate (21) in which at least one through-opening (32) is formed. The second forming tool (10) has at least one forming recess (16). The first and the second forming tools (8, 10) are arranged and designed such that, in one forming position of the forming device (2), the at least one punch projection (30) penetrates the at least one through-opening (32) and is received in the at least one forming recess (16) in the second forming tool (10).Furthermore, the stamp element (18) includes a cavity (42) which is bounded on one side by a wall surface (44), and a passage channel (46) which is connected to the cavity (42) via an opening (48) in the wall surface (44). A valve device (55) for opening and closing the opening (48) in the wall surface (44) is provided in the cavity (42).