Multi-Jig Foaming Apparatus Vertical Stacking
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Solution Overview
Problem
Existing foaming apparatuses for household appliances have a large footprint, are complex, and limited in production flexibility due to the need for complex rotating drums and long occupation times during the expansion and crosslinking of insulating materials.
Innovation Solution
A multi-jig foaming apparatus with a reduced footprint, featuring two vertically movable jig portions and lifting trolleys for loading and unloading, allowing simultaneous operation on multiple jigs without the need for rotating drums, enabling independent operation and flexibility in product handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single containment jig is used for foaming operation, then the apparatus structure is simple, but the productivity is low due to long occupation time during expansion and crosslinking
Solution Approach 1:
The containment jig is divided into multiple independent jig portions (first, second, third, fourth portions) that can operate simultaneously. Each jig portion can independently hold and process a product, allowing parallel foaming operations to increase productivity without requiring a completely new apparatus design.
Solution Approach 2:
Multiple jig portions are combined within a single apparatus framework, sharing common support structures and control systems. This merging approach enables simultaneous operations on multiple products while maintaining structural simplicity and avoiding the need for separate standalone jigs for each operation.
2Productivity
If rotating drums with multiple jigs are used, then productivity increases through simultaneous operation, but the footprint and device complexity increase significantly
Solution Approach 1:
Instead of arranging multiple jigs horizontally on a rotating drum (consuming large floor space), the invention stacks jig portions vertically one above another. This vertical arrangement allows multiple simultaneous operations while maintaining a compact footprint similar to a single-jig apparatus, effectively utilizing the vertical dimension to increase productivity.
3Productivity
If rotating drums with multiple jigs are used, then productivity increases, but the device complexity and manufacturing cost increase
Solution Approach 1:
The apparatus is segmented into independent jig portions that can be manufactured separately and assembled, simplifying the overall structure compared to a monolithic rotating drum. Each jig portion operates independently with its own support mechanism, reducing the complexity of interconnected moving parts.
Solution Approach 2:
Individual support mechanisms act as intermediaries between the fixed frame and each movable jig portion, simplifying the transmission of motion and force. This approach avoids the complex gear systems and drive mechanisms required by rotating drums, using instead simple vertical translation mechanisms for each jig.
4Reliability
If long occupation time is allowed for expansion and crosslinking, then the insulating material achieves proper dimensional stability, but the productivity decreases due to idle apparatus time
Solution Approach 1:
While one jig portion is occupied with expansion and crosslinking (requiring idle time), other jig portions simultaneously perform loading, injection, or unloading operations. This continuous utilization of different jig portions ensures that the apparatus as a whole remains productive throughout the entire cycle, eliminating idle time.
Solution Approach 2:
Products are pre-positioned and prepared in earlier jig portions before reaching the injection stage. This preliminary preparation allows the expansion and crosslinking process to occur simultaneously with other productive operations in parallel jigs, maximizing utilization of the occupation time required for material stabilization.
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 achieves a compact and economical structure with increased production flexibility, allowing simultaneous operation on multiple jigs and reducing downtime, while maintaining the simplicity of traditional foaming techniques.
Implementation Method 1
the injected material must act as an effective insulating layer. Significant pressure forces develop during the expansion process of the injected material
Implementation Method 2
during the expansion and crosslinking step of the expandable material. Once the crosslinking of the expandable material is terminated, the latter acquires a dimensional stability
Implementation Method 3
the lower jig portion is mounted vertically movable on a frame by means of individual lifting trolleys and individual guides
Implementation Method 4
the insulating layer is an important component for preventing a thermal dispersion between the inside and the outside of the refrigerator
Data Source
AI summary
A foaming method and apparatus for products comprisinga frame (T) on which a first containment jig mould (1) is supported,at least one foaming unit, anda loading trolley (20) provided with a controlled conveyor (21) for transferring said components from an inlet line (Li) inside said containment jig (1), wherein it includesat least a second containment jig (10) arranged above said first containment jig (1) constrained to the same fixed frame (T),a removal trolley (30) arranged on the side opposite said loading trolley (20) with respect to said containment jigs (1, 10), between said containment jigs (1, 10) and an outlet line (Lu), whereinsaid loading trolley (20) and removal trolley (30) are vertically movable, by means of respective controlled lifts (22, 32), between a lower position and one or more service positions in which they are arranged adjacent to said jigs (1, 10).