Multi-Segment Forming Mold for Reduced Container Parting Lines
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Solution Overview
Problem
Conventional metal container manufacturing processes require numerous stages, leading to increased space and maintenance costs, material brittleness, and limitations in producing complex geometries and high-speed, high-throughput forming.
Innovation Solution
A rotary-turret system with multi-segment molds and low-profile electromagnetic coils that use electrical energy to form containers in a continuous, high-speed process, reducing the number of stages needed and enabling the production of complex shapes and thin-walled containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cold-forming processes are used to produce metal containers, then the containers can be manufactured with standard tooling, but the material becomes more brittle and requires numerous forming stages (50 or more)
Solution Approach 1:
The patent replaces conventional mechanical cold-forming processes with electromagnetic forming technology. Electromagnetic coils generate pulsed magnetic fields that induce eddy currents in the container wall, creating electromagnetic forces that deform the material without mechanical contact. This substitution eliminates the need for multiple cold-forming stages and associated tooling while maintaining forming precision.
Solution Approach 2:
The electromagnetic forming process uses pulsed electrical energy delivered in controlled sequences. The system applies periodic electromagnetic pulses to progressively shape the container through fewer stages, with each pulse carefully timed to achieve specific geometric features without the material becoming excessively brittle.
2Shape
If multiple cold-forming stages are used to produce complex container geometries, then the desired shapes can be achieved, but the production requires large amounts of space and increases maintenance costs
Solution Approach 1:
The patent merges multiple separate cold-forming operations into a single electromagnetic forming process. By using programmable electromagnetic coils and controlled pulsing sequences, the system can perform necking, flanging, shaping, and other operations that previously required distinct machine modules in a linear arrangement, all within one compact electromagnetic forming station.
Solution Approach 2:
The electromagnetic forming system uses dynamically controllable pulse sequences where the timing, amplitude, and duration of each electromagnetic pulse can be adjusted in real-time. This dynamic control allows complex geometries to be achieved by programming the electromagnetic field evolution, replacing the need for multiple static mechanical forming stages.
3Force
If conventional electromagnetic forming with wound-wire coils is used, then forming can be performed, but insufficient clearance between the domed bottom and sidewall prevents sufficient electromagnetic force delivery
Solution Approach 1:
The patent divides the electromagnetic coil into multiple discrete segments or zones along the container length. Each coil segment can be independently controlled to generate electromagnetic forces at specific locations. This segmentation allows the system to deliver sufficient electromagnetic force to the lower sidewall region even in areas with limited clearance, by concentrating electromagnetic energy where needed through targeted coil activation.
Solution Approach 2:
The electromagnetic forming system applies localized electromagnetic pulses to specific regions of the container based on the desired geometry. By controlling which coil segments are activated and their pulse parameters, the system delivers electromagnetic force precisely where needed, such as concentrating force on the lower sidewall region despite clearance limitations, rather than applying uniform force throughout.
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 system significantly reduces production stages, minimizes material brittleness, and enables high-speed, continuous processing of containers with complex geometries, improving throughput and reducing costs.
Implementation Method 1
The electromagnetic coil is configured to impart an electromagnetic force on the pre-form articles when supplied with electrical energy. The electromagnetic force is configured to urge the pre-form articles into contact with the inner surfaces of the multi-segment mold to produce the formed containers.
Implementation Method 2
When a large electrical pulse is released through the coil, an induced current pulse is produced in the wall of the container. The resulting magnetic pressure can be used to force the wall of the container outward, thereby forming the container.
Data Source
AI summary
Molds for forming formed containers with reduced or eliminated parting lines, and systems and methods of forming the formed containers, using electromagnetic radiation are disclosed. In some aspects, the forming mold includes a multi-segment mold disposed about an electromagnetic coil. The multi-segment mold having a plurality of circumferential segments, a bottom mold section and an annular ring. Each of the circumferential segments including an inner surface wherein the plurality of inner surfaces defines a desired shape of the formed containers. The bottom mold section being adapted to hold and move the pre-form articles about an electromagnetic coil and into and out of the forming mold. The annular ring being adapted to hold, seal and optionally shape a top section of the pre-form articles so as to reduce or eliminate parting lines on the surface of the formed containers.