Horizontal Axis Carousel Molding Machine with Poppet Valve Stripping
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Solution Overview
Problem
Vertical axis carousel-type machines for molding plastic articles face challenges such as high mold forces and equipment weight, leading to bending moments on bearings and shafts, increased maintenance, energy consumption, and space requirements.
Innovation Solution
The design incorporates a mold core with a hollow forming pin and poppet valve for assisted stripping, a mold cavity with coolant passages for temperature control, and e-beam welding for component assembly, allowing for reduced forces on the support frame and efficient energy use while minimizing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical axis carousel-type machines are used for molding plastic articles, then the molding function is achieved, but the mold forces and equipment weight create bending moments on bearings and shaft, increasing maintenance requirements
Solution Approach 1:
The patent inverts the traditional vertical axis carousel design by using a horizontal axis carousel. This inversion changes the direction of gravitational force and mold forces from creating bending moments on vertical shafts to creating axial loads on horizontal bearings, thereby reducing the bending moments and associated maintenance requirements on support structures
Solution Approach 2:
The patent replaces the mechanical support system with horizontal bearings and shafts that are better suited for handling radial and axial loads, substituting the vertical bearing arrangement that suffered from bending moments. This mechanical substitution optimizes the load path and reduces stress on support components
2Power
If vertical axis carousel-type machines are used for molding plastic articles, then the molding function is achieved, but the amount of energy needed to operate the machine increases
Solution Approach 1:
By inverting the carousel axis from vertical to horizontal, the patent reduces the energy required to overcome gravitational effects on moving components and optimizes the mechanical advantage of the molding mechanism, thereby reducing overall energy consumption while maintaining effective mold forces
3Area of stationary object
If vertical axis carousel-type machines are used for molding plastic articles, then the molding function is achieved, but the amount of floor space required per machine increases
Solution Approach 1:
The patent transitions from a vertical space utilization (vertical axis carousel occupying vertical floor space) to horizontal space utilization (horizontal axis carousel occupying horizontal floor space), effectively changing the dimensional footprint and reducing the vertical clearance requirements while maintaining molding capacity
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 the forces on the support frame and bearings, decreases maintenance needs, and optimizes energy usage while minimizing space requirements, enhancing the operational efficiency and stability of the molding machine.
Implementation Method 1
A spring preferably biases the valve element to a closed position. The spring preferably comprises a coil spring captured in compression between the valve element and the forming pin.
Implementation Method 2
The poppet valve is operatively coupled to the forming pin and responsive to movement of the forming pin during operation to open the poppet valve and assist stripping of molded articles from the mold core. In the preferred embodiment, a spool valve feeds air under pressure through an air passage to open the poppet valve.
Implementation Method 3
The seat and insert have opposed surfaces that form first coolant passages between the seat and the insert, and the seat has second coolant passages for connection to the feed and return passages in the machine for circulating coolant from the machine through the mold cavity and back to the machine.
Implementation Method 4
The components preferably are secured to each other by e-beam welding, which localizes the heating to the mating surfaces and allows the assembled components to cool rapidly and retain their hardnesses.
Data Source
AI summary
A mold core includes a forming pin having a hollow interior and an end wall. A passage, preferably in the form of a hollow tube, extends into the hollow interior of the forming pin and has an end sealingly secured at a position spaced from the end wall of the forming pin. A poppet valve is disposed on the end wall of the forming pin. The poppet valve is responsive to air pressure within the passage to open and permit flow of air through the end wall of the forming pin to assist stripping of molded articles from the mold core. The poppet valve includes a valve element having an outer end at the end face of the forming pin and an inner end adjacent to the end of the passage. A spring preferably biases the valve element to a closed position. The spring preferably comprises a coil spring captured in compression between the valve element and the forming pin.