Glass Container Hot Forming Length Control
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Solution Overview
Problem
Glass container manufacturing faces challenges due to manufacturing tolerances in wall thickness and length, leading to excess mass and length issues, resulting in increased rejects and costs, particularly in the funnel-shaped end section and support shoulder, and previous methods fail to effectively compensate for these tolerances.
Innovation Solution
A method that involves determining the individual surface mass of glass container blanks to calculate the optimal total longitudinal extent of semi-finished products, allowing for hot forming without the need for cutting, thereby reducing manufacturing tolerances and eliminating excess mass and length, ensuring consistent and high-quality glass containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical cutting is used to trim excess length from glass container blanks, then length tolerance is improved, but surface quality deteriorates due to glass particles and contamination
Solution Approach 1:
The harmful mechanical cutting step is completely removed from the process. Instead of cutting to remove excess length, the invention extracts only the necessary amount of glass material during the blowing process itself, forming the final length directly without subsequent trimming operations, thereby eliminating surface contamination from cutting particles
Solution Approach 2:
The mechanical cutting system is replaced with a controlled material deposition system during the blowing process. The glass material is deposited and formed to the exact required length through controlled blowing parameters, substituting post-forming mechanical removal with precise during-forming material placement
2Manufacturing precision
If excess mass is provided in glass container blanks to compensate for hot forming losses, then manufacturing tolerance is improved, but productivity deteriorates due to increased material waste
Solution Approach 1:
The invention implements feedback control by measuring the actual glass material properties and hot forming behavior, then using this information to precisely control the blowing process parameters. This ensures that exactly the right amount of glass material is used, eliminating the need for excessive material provision while maintaining dimensional accuracy
Solution Approach 2:
The invention changes the process parameters during blowing (temperature, pressure, timing) to control material flow and deformation precisely. By optimizing these parameters, the process achieves accurate dimensional control without requiring excess material to compensate for variability, thereby improving material efficiency
3Manufacturing precision
If mechanical cutting is used to achieve precise length, then manufacturing precision is improved, but productivity deteriorates due to additional process steps and waste
Solution Approach 1:
The invention performs the length determination action preliminarily during the blowing process itself rather than as a subsequent cutting operation. The glass material is formed to the exact final length during the primary forming stage, eliminating the need for secondary length adjustment operations and reducing total production cycle time
Solution Approach 2:
The invention merges the length control function with the primary forming operation. Instead of separate operations for forming and length adjustment, the blowing process simultaneously achieves both shape formation and precise length determination in one integrated operation, improving productivity
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 approach enables the production of glass containers with significantly lower manufacturing tolerances and higher precision, reducing rejects and manufacturing time while maintaining high product quality and accuracy.
Implementation Method 1
the glass container blank is heated at least in sections to high temperature in a known manner and then shaped using a forming tool
Implementation Method 2
shaped using a forming tool to define its shape
Data Source
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AI summary
The present invention relates to a method for producing a glass container, such as a glass syringe or a glass ampoule, with a shape-defined dispensing section and optionally a shape-defined counter-surface, from a glass container blank, wherein the areal mass of the glass container blank is determined indirectly or directly and the total longitudinal extent of the glass container to be produced is determined on the basis of the determined areal mass.