Movable Mold Insert for Thermoform Film Holding
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Solution Overview
Problem
Thermoform packaging machines face challenges in managing tensile forces created by undercuts during the formation of stand-up packages, as existing clamp chains are unable to effectively handle these forces, leading to film displacement.
Innovation Solution
The introduction of a forming tool lower part with movable mold inserts that include undercuts, allowing the film to be clamped between the forming tool upper and lower parts, eliminating the need for clamp chains to manage tensile forces, and utilizing a common lift drive for synchronized movement of multiple mold inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamp chains are used to hold the formed film during opening of the forming tool, then the film can be supported, but the tensile forces due to undercuts will pull the film out of the clamp chains
Solution Approach 1:
The mold insert is made movable relative to the forming tool lower part, allowing it to be positioned in a retraction state where it clears the trough during film removal. This dynamic positioning eliminates the need for clamp chains to bear tensile forces, as the mold insert itself manages the film holding function during critical operations.
Solution Approach 2:
The forming tool is divided into a stationary forming tool lower part and a movable mold insert. This segmentation allows the mold insert to be independently controlled and retracted, separating the forming function from the film holding function during tool opening, thereby eliminating the need for complex clamp chain systems.
2Device complexity
If the mold insert is moved downward into the forming tool lower part, then tensile forces are no longer borne by clamp chains, but the film must remain clamped between forming tool upper and lower parts
Solution Approach 1:
The film clamping function is merged into the forming tool upper and lower parts themselves. When the mold insert is retracted, the forming tool lower part and upper part naturally hold the film through their structural design, eliminating the need for separate clamp chains while maintaining secure film holding during the forming process.
3Productivity
If multiple mold inserts are used to form stand-up packages, then productivity increases, but synchronization of their movement becomes necessary
Solution Approach 1:
Multiple mold inserts are combined on a single common lift drive mechanism. This allows all mold inserts to be synchronized automatically through the shared drive system, eliminating the need for multiple independent drive systems while maintaining the productivity benefits of multiple simultaneous forming operations.
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 solution enables the efficient formation of stand-up packages with undercuts without film displacement, allowing for precise and cost-effective operation by moving mold inserts relative to the forming tool lower part, thereby reducing the risk of collision and enabling further transport of formed troughs.
Implementation Method 1
The lift drive can comprise a pneumatic cylinder or a servomotor, or other suitable device, so as to allow for fast and/or precise positioning or movements of the mold insert
Implementation Method 2
The lift drive can comprise a pneumatic cylinder or a servomotor, or other suitable device, so as to allow for fast and/or precise positioning or movements of the mold insert
Implementation Method 3
thermoforming the film into a mold insert accommodated in the interior of the forming tool lower part
Data Source
AI summary
The present invention relates to a thermoform packaging machine with a forming station. The forming station can include a forming tool lower part with at least one mold insert that is movable relative to the forming tool lower part. The present invention also relates to a method of forming a film including the step of moving the mold insert, relative to the forming tool lower part and the formed film, to a removal position while the film is clamped between the forming tool upper part and the forming tool lower part.