Hot-Forming Tool Thermal Management for Glass Containers
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Solution Overview
Problem
The existing hot-forming process for pharmaceutical primary packaging means faces issues with geometrical deviations and particle contamination due to excessive oil usage, leading to frequent cleaning and downtime, as well as uncontrolled cooling and potential oil ignition, which affects the quality and efficiency of glass container production.
Innovation Solution
A hot-forming tool with a rotatably mounted forming roller in thermal contact with a non-co-rotating heat sink that provides internal cooling, reducing the need for external oil or air cooling and minimizing oil usage, while allowing for efficient heat dissipation and quick tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large quantities of forming oil are used for lubricating and cooling the forming tools, then friction is reduced and tool temperatures are lowered, but deposits accumulate on the forming tools leading to geometrical deviations, particle contamination, and production interruptions
Solution Approach 1:
The patent extracts the harmful function of forming oil by replacing it with a forming paste composed of solid lubricant particles (graphite, PTFE, MoS2) in a binder matrix. This paste is applied in controlled amounts and does not burn or create deposits like liquid oil, thereby eliminating particle contamination while maintaining lubrication and cooling functions
Solution Approach 2:
The invention changes the physical state of the lubricant from liquid (forming oil) to semi-solid (forming paste). This parameter change allows the lubricant to adhere to the forming tools, providing sustained lubrication without the volatility and combustion issues of liquid oil, thus preventing deposits and contamination
2Manufacturing precision
If forming tools are dismantled and cleaned regularly to remove deposits, then production quality is maintained, but production interruptions occur and start-up losses are incurred
Solution Approach 1:
The forming paste is designed as a consumable material that is applied fresh to the forming tools for each production run or shift. Instead of attempting to prevent all deposits indefinitely, the system accepts controlled deposit formation and simply replaces the paste regularly, avoiding costly tool dismantling and cleaning while maintaining quality
Solution Approach 2:
The forming paste is applied to the forming tools in advance before production begins. This preliminary application creates a protective layer that prevents glass adhesion and minimizes deposits during the forming process, eliminating the need for mid-production cleaning interruptions
3Temperature
If cooling air is used to cool the forming tools, then tool temperatures are reduced, but the forming oil is swirled and distributed causing severe contamination of the forming machine and production environment
Solution Approach 1:
The patent converts the harmful effect of strong air flows (which swirl and distribute forming oil causing contamination) into a beneficial effect by using the same air flows to deliver the forming paste to the forming tools. The paste adheres to the tools and does not vaporize or spread like liquid oil, turning a contamination source into a delivery mechanism for the lubricant
4Temperature
If strong air movement is used for cooling, then tool temperatures are controlled, but particles reach the forming surfaces leading to rejects
Solution Approach 1:
The forming paste is a composite material consisting of solid lubricant particles (graphite, PTFE, or MoS2) dispersed in a binder matrix. This composite structure allows the paste to adhere to the forming tools and resist being blown away by air flows, while the solid particles provide lubrication without vaporizing or contaminating the environment like liquid oil
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 solution reduces rejects and downtime by maintaining consistent tool temperatures below 300°C, minimizing contamination, and extending tool service life by preventing oil residue deposits and ensuring precise temperature control.
Implementation Method 1
the forming roller is in thermal contact with the heat sink, and the heat sink has means for internal cooling, so that process heat can be transferred from the forming roller to the heat sink
Data Source
AI summary
A hot-forming tool for producing glass containers is provided. The tool includes a forming roller, a holder, and a heat sink. The forming roller has a forming surface. The holder receives the forming roller with the forming roller rotatably mounted on the holder. The heat sink is directly or indirectly connected to the holder. The forming roller is in thermal contact with the heat sink and the heat sink has an internal cooler so that process heat can be transferred from the forming roller to the heat sink.