Moulding Machine Segmented Bores for Uniform Temperature Control
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Solution Overview
Problem
Existing moulding machines face challenges in efficiently and cost-effectively providing uniform heating and cooling due to complex and expensive channel formation in moulds, leading to potential leaks, blockages, and uneven temperature distribution, affecting the quality and reliability of plastic articles.
Innovation Solution
A moulding machine comprising non-complementary moulds with bores connected by grooved blocks, allowing for flexible channel configurations and easy maintenance, which simplifies the formation of internal channels for fluid circulation, ensuring even temperature distribution and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If channels are formed by CNC milling in sandwich construction moulds, then heating and cooling can be provided, but the process becomes complex, time-consuming and expensive
Solution Approach 1:
The mould is divided into two separate bodies (first body and second body) that are joined together. Channels are formed in each body independently and then connected through joining surfaces, eliminating the need for complex precision cutting through the entire mould thickness. This segmentation simplifies manufacturing while maintaining heating and cooling functionality.
Solution Approach 2:
The channel network is created by nesting simple channel structures within each mould body, where channels in the first body align and connect with channels in the second body. This nested arrangement allows complex fluid circulation paths to be achieved through simple, easily manufacturable components.
2Reliability
If a gasket is used to seal channels in sandwich construction moulds, then sealing is achieved, but leaks and blockages occur when the gasket fails requiring complete dismantlement
Solution Approach 1:
The mould is segmented into two separable bodies with channels formed independently in each. The joining surface between bodies provides the seal, eliminating the need for separate gaskets. This segmentation allows easy disassembly and reassembly for maintenance without complex gasket replacement procedures.
Solution Approach 2:
The joining surface acts as an intermediary element that both connects the two mould bodies and provides the sealing function. This eliminates the need for separate gasket components while maintaining reliable sealing, and simplifies maintenance as the joining surface can be easily accessed and serviced.
3Device complexity
If a single continuous long channel is formed through the mould, then fluid circulation is simplified, but uneven temperature distribution occurs affecting product quality
Solution Approach 1:
The channel system is segmented into multiple separate channels formed in the first and second mould bodies. These channels can be independently configured to optimize fluid distribution patterns, allowing for more uniform temperature distribution across the mould while maintaining relatively simple channel structures.
Solution Approach 2:
The channel configuration can be locally optimized in different regions of the mould by independently designing channels in the first and second bodies. This allows tailored fluid distribution to specific areas that require different temperature control, achieving uniform overall temperature distribution while keeping individual channel structures simple.
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 solution provides a cost-effective, versatile, and reliable moulding machine with improved temperature control and reduced maintenance complexity, resulting in consistent quality of moulded products.
Implementation Method 1
heating the moulds by conduction while the moulds are open
Implementation Method 2
circulation of heated or cooled fluid, such as oil, through the bores
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A moulding machine comprises first and second non-complementary moulds (20a, 20b). The first mould (20a) defines a female mould cavity (36). The second mould (20b) defines a flat moulding surface (30). The first and second moulds (20a, 20b) are movable between a first position in which the moulds are apart and the female mould cavity (36) and the flat moulding surface (30) both face upwards, and a second position in which the moulds are brought together and the flat moulding surface faces into and closes the female mould cavity to form a completely enclosed cavity. Each mould (20a, 20b) has a plurality of bores (22) formed through it and with an opening (24) at each end. At least two of the bores (22) are connected to each other by a block (38) positioned over the opening at one end of one bore and the opening at the end of another bore. The block (38) is formed with a groove (40) which connects the openings to each other.