Movable Blowing Assembly for Thermoplastic Container Forming
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Solution Overview
Problem
Dual-stage machines for producing thermoplastic containers face limitations in productivity and cost due to large dimensions, slow mould opening, and high production costs associated with large blowing moulds, which hinder efficient cooling and format-changing operations.
Innovation Solution
A machine with a movable blowing assembly that can be displaced in the longitudinal direction, featuring a smaller number of blowing cavities than injection/moulding cavities, allowing for rapid format-changing and reduced downtime, along with a control unit to adjust blowing positions and alignment, and actuating mechanisms for efficient mould operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of blowing cavities are used in the blowing mould to match the injection mould capacity, then the production output is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The blowing assembly is divided into multiple identical modular units, each containing a subset of blowing cavities. These modules can be independently manufactured, assembled, and replaced. The patent applies segmentation by creating a blowing assembly with fewer cavities per module that can be dynamically repositioned to match different injection mould configurations, reducing the complexity of manufacturing a single large-scale blowing mould with numerous cavities.
Solution Approach 2:
The blowing assembly is made movable along the longitudinal direction through guides and actuating mechanisms, allowing dynamic repositioning between different blowing positions. This dynamic capability enables a single blowing assembly with fewer cavities to serve multiple injection mould configurations, replacing the need for fixed, large-capacity blowing moulds and reducing manufacturing costs while maintaining high productivity.
2Adaptability or versatility
If the blowing assembly is made movable to enable rapid format-changing, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The movable blowing assembly is designed as a universal component that can serve multiple injection mould configurations and container formats. By making the blowing assembly adaptable through longitudinal movement and repositioning, a single design can replace multiple fixed blowing moulds, achieving multi-functionality that reduces overall device complexity despite the added movement capability.
Solution Approach 2:
Guides and actuating mechanisms serve as intermediary elements that enable the blowing assembly to move and reposition without requiring complex direct coupling between the blowing assembly and each injection mould configuration. These intermediaries simplify the overall system by providing standardized interfaces and movement paths.
3Productivity
If the blowing assembly is displaceable between multiple positions, then the productivity is improved through optimal cooling times, but the loss of time for position changes increases
Solution Approach 1:
The blowing assembly is positioned and configured in advance for each blowing operation, with pre-defined blowing positions corresponding to different injection mould configurations. This preliminary positioning allows the system to minimize movement during operation, reducing the time lost for position changes while maintaining optimal cooling times between injection and blowing cycles.
Solution Approach 2:
The system maintains continuous productivity by coordinating the movement of the blowing assembly with the injection and cooling cycles. The blowing assembly moves to different positions in coordination with the production rhythm, ensuring that blowing operations occur continuously without idle time, thereby minimizing the impact of position changes on overall productivity.
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 machine achieves high hourly production output with reduced production costs and faster handling, enabling optimal cooling times and versatility in container formats while minimizing downtime and energy consumption.
Implementation Method 1
an injection unit provided with a longitudinal injector
Implementation Method 2
injection into the mould of the material in the softened state
Implementation Method 3
a station for blowing the preforms, including a blowing assembly for forming finished containers
Implementation Method 4
subjected to a first mechanical moulding deformation in order to obtain a so-called preform
Implementation Method 5
the subsequent extraction of the preforms, already cooled
Data Source
AI summary
Machine for forming containers made of thermoplastic material by blow-molding preforms obtained by means of injection/molding within the machine, for which at least one longitudinal direction for feeding of the preforms between the stations thereof is defined, said machine including: an injection unit provided with a longitudinal injector; a station for molding the preforms, comprising a mold with a predefined number of cavities for injection/molding of preforms; a station for blowing the preforms, comprising a blowing assembly for forming finished containers; said blowing assembly comprising a smaller number of blowing cavities than the number of injection/molding cavities in the mold and being displaceable in both senses of the longitudinal direction on fixed longitudinal guides.