Modular Blow Molding Apparatus for Complex Resin Containers
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Solution Overview
Problem
The existing two-blow blow molding apparatus is large and costly, limiting installation locations and increasing costs, and struggles to efficiently form resin containers with complex shapes like those with handles or off-center designs while maintaining improved heat resistance.
Innovation Solution
A modular blow molding apparatus with a primary and secondary blow molding station, where preforms are injection-molded and blow-molded in stages, with transport devices managing the flow between stations, allowing for simultaneous processing and independent operation of the secondary station to form resin containers with handles or off-center designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-blow type blow molding apparatus is used to improve heat resistance of the resin container, then the heat resistance property is improved, but the apparatus size increases and installation cost increases
Solution Approach 1:
The blow molding apparatus is divided into a primary blow molding station and a secondary blow molding station that can operate independently. The primary station performs the first blow molding to create the parison, while the secondary station performs the final blow molding to form the container. This segmentation allows each station to be optimized for its specific function and reduces the overall apparatus size compared to a monolithic two-blow apparatus.
Solution Approach 2:
The secondary blow molding station is extracted as an independent unit that can be installed separately from the primary station. This extraction allows the heat treatment function to be separated from the blow molding function, enabling improved heat resistance without requiring a large integrated apparatus. The secondary station can be installed at a different location optimized for heat treatment.
2Adaptability or versatility
If a two-blow type blow molding apparatus is used to form complex shaped containers like those with handles or off-center designs, then the container shape complexity is improved, but the apparatus size increases and introduction cost increases
Solution Approach 1:
The apparatus employs dynamic positioning systems at both the primary and secondary blow molding stations. The primary station can position preforms at various locations to create off-center designs, while the secondary station can accommodate complex shapes like handles through adjustable mold positioning. This dynamic capability allows the same apparatus to produce diverse container shapes without increasing overall complexity.
Solution Approach 2:
Both the primary and secondary blow molding stations are designed with universal capabilities to handle different container types. The primary station can produce simple containers or complex parisons, and the secondary station can finish both simple and complex shapes. This multi-functionality allows a single apparatus configuration to serve multiple production needs without requiring separate specialized equipment.
3Reliability
If a two-blow type blow molding apparatus is used to improve heat resistance, then the heat resistance is improved, but the installation location is limited
Solution Approach 1:
The secondary blow molding station is extracted as an independent unit that can be installed at a different location from the primary station. This extraction provides installation flexibility, allowing the heat treatment function to be positioned in a location optimized for thermal processing while the blow molding function is positioned for ease of operation. The separated stations can be connected through a transport mechanism.
4Reliability
If preforms are blow-molded and then pooled and heat-treated in a separate process, then the heat resistance is improved, but the production time increases
Solution Approach 1:
The primary blow molding station continuously produces parisons that are immediately transferred to the secondary blow molding station for finishing and heat treatment. This continuous flow eliminates idle time between operations. The secondary station is positioned to receive parisons directly from the primary station, creating an uninterrupted production sequence that maintains heat resistance while minimizing production time.
Solution Approach 2:
The primary blow molding station performs preliminary blow molding to create the basic parison shape before the secondary station completes the final container formation and heat treatment. This preliminary action allows the secondary station to focus only on the finishing operations, reducing its cycle time and overall production time while ensuring proper heat treatment for heat resistance.
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 enables efficient formation of resin containers with improved heat resistance, reduces apparatus size, and lowers installation costs, allowing for flexible placement and the production of diverse container shapes.
Implementation Method 1
an injection molding part configured to injection-mold a plurality of the preforms simultaneously
Implementation Method 2
a primary blow molding part configured to blow-mold the preform to form a first blow-molded article
Implementation Method 3
a secondary blow molding part configured to blow-mold the first blow-molded article to form the resin container
Implementation Method 4
a first transport device including a first transport path which connects the injection molding part and the primary blow molding part, and configured to intermittently circulate and transport a plurality of the preforms and the first blow-molded article along the first transport path
Data Source
AI summary
A configuration including: a primary blow molding station including: an injection molding part configured to injection-mold a plurality of preforms simultaneously; a primary blow molding part configured to blow-mold the preform to form a first blow-molded article; and a first transport device including a first transport path and configured to intermittently circulate and transport a plurality of the preforms and the first blow-molded article along the first transport path at a predetermined interval; and a secondary blow molding station installed independently of the primary blow molding station, the secondary blow molding station including: a secondary blow molding part configured to blow-mold the first blow-molded article to form a resin container; and a second transport device configured to hold the first blow-molded article at a downstream side of the primary blow molding part in the first transport path and transport the first blow-molded article to the secondary blow molding part.