Mold Cooling System with Segmented Ducts for Uniform Heat Transfer
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Solution Overview
Problem
Existing mold cooling systems for glassware forming machines suffer from non-uniform heat dissipation, high energy costs due to excessive air pressure requirements, and the need for frequent equipment adjustments for different container sizes, which limits production speed and increases manufacturing costs.
Innovation Solution
A mold cooling system that includes a plenum chamber with adjustable cooling ducts and a cylinder-piston assembly, allowing for continuous cooling during the 360° forming cycle and programmed air flow distribution, adaptable to both parison and blowing molds, with a simplified structure that reduces equipment complexity and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air under high pressure is passed through the frame of the machine towards the mold holding clamps, then the mold cooling capacity increases, but the energy consumption increases and the heat dissipation becomes non-uniform
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits, each with its own air supply and distribution network. This allows different regions of the mold to be cooled independently with optimized air flow rates, improving overall cooling efficiency while reducing total energy consumption compared to a single high-pressure system
Solution Approach 2:
Different regions of the mold are provided with different cooling intensities based on their specific thermal requirements. The system uses locally-adjustable cooling elements that can be tuned to provide uniform heat dissipation across the mold surface, eliminating the non-uniform cooling effect of the conventional high-pressure frame-based system
2Productivity
If air under high pressure is used for mold cooling, then the cooling speed increases, but the manufacturing cost increases
Solution Approach 1:
The cooling system incorporates dynamically adjustable elements that can modify air flow rates and distribution patterns in real-time based on production requirements. This allows the system to optimize cooling performance for high-speed production while consuming less energy, thereby increasing productivity without proportionally increasing manufacturing costs
Solution Approach 2:
The system enables independent adjustment of cooling parameters (air pressure, flow rate, distribution) for different mold regions and production conditions. This flexibility allows optimization of the cooling process for maximum productivity at lower energy costs, rather than requiring continuously high-pressure air supply
3Device complexity
If the cooling system only cools molds when closed, then the equipment complexity is reduced, but the cooling efficiency decreases
Solution Approach 1:
The cooling system is designed to provide continuous cooling throughout the entire mold cycle, including during opening and closing movements. Multiple cooling zones are activated at different times to ensure the mold is cooled continuously, which increases cooling efficiency without significantly increasing equipment complexity compared to intermittent cooling systems
4Temperature
If high air pressure is used for cooling during the 360° cycle, then the cooling coverage is improved, but the energy losses increase
Solution Approach 1:
The 360° cooling cycle is divided into multiple segmented cooling zones that are activated sequentially or simultaneously based on specific thermal needs. Each zone has its own air supply circuit that can be independently controlled, providing comprehensive cooling coverage while minimizing total energy consumption by avoiding unnecessary high-pressure air supply to all zones at all times
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
The system ensures uniform heat transfer, reduces energy consumption, and allows for quick adjustments to different mold sizes, enhancing production speed and versatility while extending equipment lifespan by minimizing load on clamps and reducing maintenance costs.
Implementation Method 1
passing the air under pressure through the frame of the machine, which was directed towards the mold holding clamps
Implementation Method 2
the dissipation of heat in the mold was not uniform and therefore, it was not either in the newly formed glass container
Data Source
AI summary
The present invention relates to mold cooling method and system for a glass container forming machine of the type that comprises, at least one mold holder including mold halves, that are movable between a closed mold position for forming the glass article and an open mold position for releasing said article, each of the mold halves having axial passages for cooling each of the mold halves. A support structure having a fixed upper support section and a movable support section. Means for providing a cooling flow are coupled in coincidence with a series of openings in the movable support section. A cooling flow distributor located above the movable support section, the cooling flow distributor having a lower section in coincidence with each of the openings of the movable support section for the passage of the cooling flow and, a upper section in coincidence with each of the axial passages of each of the halves of each mold, the cooling flow distributor being movable between the closed mold position for forming the glass article and the open mold position for the releasing said article, the cooling flow distributor supplying the cooling flow through each of the openings in the movable support section to cool the halves of each mold in any position, between the closed mold position for forming the glass article and the open mold position for the release of said article. An article forming mechanism is coupled to the movable support section. A mechanism for adjusting the height of the movable support section and, consequently, adjusting the height of the article forming mechanism, the means for providing the cooling flow and the cooling flow distributor in accordance to the height of each mold.