Expandable Mandrel Positioning for Uniform Receptacle Moulding
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Solution Overview
Problem
Existing mould systems face issues with the expandable member of the mandrel system improperly positioning within the mould cavity, leading to non-uniform pressure application and potential damage or fatigue, which affects the quality and longevity of the receptacle.
Innovation Solution
A mandrel system with a moveable mandrel and expandable member, controlled by a controller, allows for precise positioning and clearance adjustment relative to the mould cavity, ensuring uniform pressure application and reducing operator input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the expandable member is positioned too far from the base of the mould cavity, then insertion is easier, but during expansion the expandable member contacts the upper part of the receptacle before filling the lower part, inhibiting further expansion and causing non-uniform pressure application
Solution Approach 1:
The mandrel system incorporates moveable components including the mandrel and expandable member that can adjust their positions relative to each other and to the mould cavity. This dynamic adjustment capability allows the system to optimize the initial positioning clearance for easy insertion while simultaneously ensuring proper engagement and uniform pressure distribution during the expansion forming process.
2Manufacturing precision
If the expandable member is positioned too close to the base of the mould cavity, then pressure application is more uniform, but the expandable member cannot be properly inserted into the mould cavity
Solution Approach 1:
The system employs dynamic positioning mechanisms that allow the expandable member and mandrel to adjust their relative positions. During insertion, the components are positioned with appropriate clearance for easy access, while during expansion, the system adjusts to ensure the expandable member engages properly with the receptacle throughout its entire length, maintaining uniform pressure distribution.
3Device complexity
If a fixed mandrel system is used, then the system structure is simpler, but the mandrel system cannot accommodate various mould geometries and requires bespoke mandrel systems for different moulds
Solution Approach 1:
The mandrel system replaces fixed structures with dynamic, adjustable components. The mandrel and expandable member can move and adjust their positions to accommodate different mould cavity geometries and dimensions. This dynamic capability allows a single standardized mandrel system to be used across multiple mould types, eliminating the need for bespoke mandrels for each mould while maintaining structural efficiency.
Solution Approach 2:
The moveable mandrel system is designed as a universal component that can adapt to various mould geometries through position adjustment. Rather than requiring dedicated fixed mandrels for each mould type, this universal system performs multiple functions across different mould configurations, reducing overall system complexity and component variety.
4Device complexity
If manual positioning of the expandable member is used, then the system requires less complex control mechanisms, but operator input is excessive and positioning precision is reduced
Solution Approach 1:
The system incorporates automatic control mechanisms that enable the mandrel and expandable member to self-position and self-adjust during operation. The controller automatically manages the positioning and movement sequences, reducing the need for manual operator intervention while maintaining high positioning precision and operational efficiency.
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
Improves the quality and longevity of the receptacle by ensuring uniform pressure application and reducing the need for bespoke mandrel systems, while accommodating various mould geometries.
Implementation Method 1
the mandrel comprises one or more holes through which a fluid is flowable in use from an interior of the mandrel to an exterior of the mandrel to expand the expandable member
Implementation Method 2
ensuring uniform pressure application
Data Source
Figure 1
Figure 2
Figure 3(a)~3(d)
AI summary
A mould (102, 103, 15, 201, 25) system for moulding a receptacle (22) is described. The mould (102, 103, 15, 201, 25) system comprises a mould (102, 103, 15, 201, 25) comprising a mould cavity (115, 203) and an opening (117), and a mandrel (123, 125, 403) system comprising a reference point (133), a mandrel (123, 125, 403) and an expandable member (123, 125). The mandrel (123, 125, 403) is at least partially located, or at least partially locatable, inside the expandable member (123, 125) and comprises one or more holes (135) through which a fluid is flowable in use from an interior of the mandrel (123, 125, 403) to an exterior of the mandrel (123, 125, 403) to expand the expandable member (123, 125). When the mandrel (123, 125, 403) is at least partially located inside the expandable member (123, 125), the mandrel (123, 125, 403) system is positionable relative to the mould (102, 103, 15, 201, 25) such that the reference point (133) is at a fixed position relative to the mould (102, 103, 15, 201, 25) and the mandrel (123, 125, 403), and the expandable member (123, 125) extend into the mould cavity (115, 203) through the opening (117) such that there is a clearance between the expandable member (123, 125) and a base (119) of the mould cavity (115, 203) opposite the opening (117). The expandable member (123, 125) and at least a part of the mandrel (123, 125, 403) are moveable relative to the reference point (133) to vary the clearance.