Modular Mold Insert System for Quick Blow Molding Changeovers
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Solution Overview
Problem
Conventional extrusion-type blow mold machines require labor-intensive and time-consuming mold changes, with heavy and large molds necessitating significant manpower and machinery, leading to prolonged shutdown periods.
Innovation Solution
A modular mold insert system with smaller, lighter components that align opposite each other, featuring insert receiving regions and gas injection regions, allowing for quick and efficient replacement of only the necessary mold parts, reducing the size and weight of interchangeable elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional molds are used, then the mold structure is complete and functional, but the mold change time is 50-60 hours and requires significant manpower
Solution Approach 1:
The mold is divided into a stationary mold body and multiple removable insert components. Each insert can be independently removed and replaced without replacing the entire mold assembly. This segmentation reduces mold change time from 50-60 hours to 4 hours or less, while the stationary mold body remains reusable.
Solution Approach 2:
The critical variable portion of the mold (the insert containing the mold cavity) is extracted as a separate removable component from the stationary mold body. This allows only the necessary portion to be changed when producing different bottle types, eliminating the need to replace the entire heavy mold assembly.
2Weight of moving object
If conventional molds are used, then the mold provides complete molding functionality, but the mold weight is very heavy requiring additional manpower and machinery
Solution Approach 1:
The heavy mold assembly is segmented into a stationary fixed body and lighter removable inserts. The inserts contain only the necessary mold cavity portions and can be handled individually with much less effort than the complete conventional mold, improving ease of operation during mold changes.
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
Significantly reduces mold change time from 50-60 hours to four hours or less, enabling additional production days by minimizing the need to replace entire molds, thus enhancing operational efficiency.
Implementation Method 1
gas injection regions for introducing blow gas from outside the mold bodies to the mold cavities for forming the bottles
Data Source
AI summary
A mold insert set is provided for use with a mold system having first and second mold bodies, the first and second mold bodies aligning opposite each other during a molding process. Each of the mold bodies has at least one insert receiving region for replaceably receiving an insert of the mold insert set. Each of the inserts has an insert body, a mold cavity formed in the insert body, the mold cavity being for forming an object, and an opening in the mold cavity for aligning with a gas injection region of the mold body in which the insert is received. The gas injection region is where blow gas is introduced to the mold cavity for forming the object.