Multi-Cavity Mould Smooth Periphery Thermoforming
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Solution Overview
Problem
Conventional thermoforming machines produce thin-gauge plastic products with sharp edges, which can damage sealing films and are not suitable for multiple sealing technologies, and existing methods to form smooth peripheries are inefficient and costly.
Innovation Solution
A multi-cavity mould with reconfigured supporting blocks and a heating element that extends the peripheral flange and directs hot air to gradually increase its thickness, forming a smooth periphery without exceeding the medium thickness of the thermoformed sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional thermoforming machines produce thin-gauge plastic products, then production efficiency is high, but the products have sharp edges that can damage sealing films
Solution Approach 1:
The patent applies preliminary action by extending the peripheral flange during the forming process itself, before the product leaves the mould. The reconfigured supporting blocks with tapered zones create vertical channels that pre-extend the flange, and the heating element then applies heat to smooth the periphery before sealing operations occur, preventing damage to sealing films
Solution Approach 2:
The patent changes physical parameters by applying heat to the peripheral flange material, transforming it from a sharp-edged state to a smooth, rounded state. The heating element raises the temperature of the flange material above its softening point, allowing it to be reshaped into a smooth periphery that eliminates harmful sharp edges
2Adaptability or versatility
If existing methods are used to form smooth peripheries, then product compatibility with sealing technologies improves, but production efficiency decreases and costs increase
Solution Approach 1:
The patent merges the smooth periphery formation process with the existing thermoforming cycle by integrating the reconfigured supporting blocks and heating element directly into the mould system. This combination eliminates the need for separate post-forming operations, maintaining high production efficiency while achieving compatibility with multiple sealing technologies
Solution Approach 2:
The patent creates a multi-functional system where the reconfigured supporting blocks serve both structural support and flange extension functions, while the heating element provides both heating and periphery smoothing functions. This universal approach enables the same system to produce products compatible with multiple sealing technologies (overwrap, vacuum-sealed, modified atmosphere packaging) without requiring different equipment for each application
3Adaptability or versatility
If the peripheral flange thickness is increased to form smooth peripheries, then sealing compatibility improves, but material usage efficiency decreases
Solution Approach 1:
The patent changes the thickness parameter of the peripheral flange dynamically during processing. The reconfigured supporting blocks with tapered zones extend the flange and reduce its thickness in the vertical channels, creating a thinner profile that uses less material. The heating element then smooths this thinner flange to achieve sealing compatibility without requiring excessive material thickness
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 allows for the production of thermoformed products with smooth peripheries that can be used with multiple sealing technologies, reducing damage and production costs while maintaining efficient use of thermoplastic material.
Implementation Method 1
directs hot air to gradually increase its thickness
Implementation Method 2
heating element that extends the peripheral flange and directs hot air to gradually increase its thickness
Data Source
AI summary
A multi-cavity mold (1) for a thermoforming machine used in high-volume, continuous thermoforming of thin-gauge plastic products (2) from a preheated thin-gauge thermoplastic sheet (3) comprising an upper tool (11) and a lower tool (12) arranged in a cooperating manner; the lower tool (12) comprising cavities (8) in which cavity molds (8′) are placed and base plates (91) from which supporting blocks (92) extend perpendicularly over a predetermined total height (a), situated between adjacent cavities (8), each supporting block (92) comprising two zones, a first substantially rectangular shaped zone (92a) and a second substantially isosceles trapezoid shaped zone (92b) in a vertical cross section through a y-z plane and two vertical channels (81) to alter, during forming of the products (2), a thickness of a peripheral flange (B), to decrease from a medium thickness (t) to a lesser thickness (t1).