Integrated Blow-Molding of Plastic and Shape Memory Alloy Elements
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Solution Overview
Problem
The existing blow-molding process for manufacturing plastic and shape-memory material elements in the automotive industry requires separate processing procedures, leading to increased production time and costs due to the need for dedicated machines and multiple operations.
Innovation Solution
An integrated molding method using a hollow mold with a housing for shape-memory alloy elements, where a high-temperature parison is expanded to compress and memorize the alloy's shape within the mold, allowing simultaneous molding of plastic and shape-memory alloy elements in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate processing procedures are used for plastic elements and shape-memory alloy elements, then each element can be processed with dedicated machinery, but production time increases and manufacturing costs rise
Solution Approach 1:
The patent combines the molding of plastic elements and shape-memory alloy elements into a single integrated blow-molding process. The parison simultaneously forms both the plastic component and the shape-memory alloy component within one mold cycle, eliminating the need for separate processing procedures and dedicated machinery for each material type.
Solution Approach 2:
The blow-molding process is designed to handle multiple material types (plastic and shape-memory alloy) within a single universal process framework. The mold and parison configuration enable simultaneous formation of different component types using the same equipment and operational sequence, achieving multi-functionality in the manufacturing system.
2Reliability
If separate processing procedures are used for plastic elements and shape-memory alloy elements, then specialized equipment can be optimized for each material, but manufacturing costs increase
Solution Approach 1:
The patent merges the manufacturing of plastic and shape-memory alloy elements into a single blow-molding operation. By combining these previously separate processes, the invention eliminates the need for multiple dedicated machines and reduces overall manufacturing complexity, thereby lowering production costs while maintaining quality through integrated process control.
Solution Approach 2:
The blow-molding process serves as a universal manufacturing method that can produce both plastic elements and shape-memory alloy elements using the same equipment and process parameters. This multi-functionality reduces the need for specialized equipment for each material type, decreasing capital investment and operational costs.
3Reliability
If separate processing procedures are used for plastic elements and shape-memory alloy elements, then each process can be optimized independently, but the production chain dimensions increase
Solution Approach 1:
The patent combines multiple processing steps into a single integrated blow-molding operation. The parison is formed and molded in one continuous process, eliminating the need for separate processing chains for plastic and shape-memory alloy elements. This reduction in process steps directly decreases the dimensions and complexity of the production chain.
Solution Approach 2:
The blow-molding process acts as a universal manufacturing platform that handles both plastic and shape-memory alloy elements through the same process sequence. This multi-functional approach consolidates what would otherwise require separate processing lines, reducing the overall complexity and spatial dimensions of the production chain.
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 reduces the number of operations and eliminates the need for dedicated machines, thereby decreasing manufacturing costs and time while enabling the production of plastic and shape-memory alloy elements with memorized geometric shapes.
Implementation Method 1
blowing air into the parison in order to expand it until it adheres to the inner surface 2a of the volume 2, thus forming the object 4 defined by the shape of the inner surface 2a, hence compressing the element 6 in a second operating shape
Implementation Method 2
alloys that change their shape in the space assuming specific shapes at specific temperatures that are higher than transition temperatures that can be memorized during the manufacturing process
Implementation Method 3
After the expansion, the already formed object needs to cool down
Data Source
Figure 1A~1B
Figure 2A~4
AI summary
Device and method for the integrated blow-molding production of a plastic material element and of a shape-memory material element, said device and relative method enabling the blow-molding of a thermoplastic object and, at the same time, the training of a shape-memory material element.