Multistage Temperature Adjustment Station for Resin Preform Cooling
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Solution Overview
Problem
Existing blow molding apparatuses struggle to manufacture high-quality resin containers with uniform thickness and minimal whitening, especially when the cooling time after injection molding is shortened, leading to temperature unevenness and excessive cooling of the neck portion.
Innovation Solution
A resin container manufacturing apparatus with a temperature adjustment station having a multistage structure, where the uppermost stage has the highest temperature and the mold surface temperature of lower stages is lower than the glass transition temperature of the preform by 10° C. or more, allowing for effective temperature adjustment and prevention of excessive cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cooling time after injection molding is shortened to increase productivity, then the molding cycle time is reduced, but temperature unevenness occurs in the preform and the neck portion is excessively cooled
Solution Approach 1:
The temperature adjustment station is divided into multiple temperature adjustment units with different temperatures. The preform passes through these units in sequence, with each unit providing a specific temperature zone. This segmentation allows different parts of the preform to receive appropriate temperature treatment, preventing excessive cooling while maintaining productivity.
Solution Approach 2:
Different sections of the temperature adjustment station are assigned different temperatures according to the specific cooling requirements of various preform regions. The neck portion receives warmer treatment to prevent excessive cooling, while other sections receive appropriate cooling. This local quality approach ensures temperature uniformity without extending the overall cycle time.
2Device complexity
If a conventional single-temperature cooling system is used, then the device structure is simple, but the preform cannot achieve uniform temperature distribution
Solution Approach 1:
The cooling system is segmented into multiple independent temperature adjustment units, each capable of operating at a different temperature. This segmentation transforms a simple single-temperature system into a multi-temperature system that can achieve uniform temperature distribution across the preform while maintaining reasonable structural complexity.
Solution Approach 2:
The temperature adjustment units can independently control their temperatures, creating a dynamic temperature distribution along the preform path. This dynamic capability allows the system to adapt to different cooling requirements at different locations, achieving uniform temperature distribution without requiring an overly complex static structure.
3Productivity
If the preform is rapidly cooled to shorten processing time, then productivity increases, but thickness unevenness and whitening occur in the manufactured container
Solution Approach 1:
The rapid cooling process is segmented into multiple stages with different cooling rates. The preform first passes through warmer temperature adjustment units that prevent excessive cooling and quality defects, then progresses to cooler units that achieve the desired cooling rate for productivity. This segmented approach maintains container quality while enabling rapid overall cooling.
Solution Approach 2:
The temperature adjustment station performs preliminary temperature conditioning of the preform before blow molding. By pre-adjusting the temperature distribution through multiple units, the system prevents thickness unevenness and whitening from occurring during subsequent processing, thereby maintaining high productivity without sacrificing quality.
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 apparatus enables the production of high-quality resin containers with reduced thickness unevenness and whitening, even when the molding cycle time is shortened, by ensuring a suitable temperature distribution and preventing excessive cooling of the preform.
Implementation Method 1
The temperature adjustment station uses a heating pot mold (heating block) and a heating rod, and adjusts the temperature of the preform by heating the preform in a non-contact manner.
Implementation Method 2
Outer peripheral surfaces of a bottom portion of the preform and a lower body portion continuous to the bottom portion are mechanically closely contacted and securely cooled with a cooling pot
Data Source
AI summary
A mold for temperature adjustment including a plurality of temperature adjustment blocks aligned in an upper and lower direction. An insulation mechanism is provided at an uppermost stage of the temperature adjustment block.