Neck Crystallization System Rectangular Stage Layout
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Solution Overview
Problem
Existing neck crystallization systems face challenges in efficiently processing wide-mouth containers due to increased neck diameter, leading to reduced throughput, deflection of transfer chains, and difficulties in system layout, especially when trying to maintain a compact design for factory installations.
Innovation Solution
The neck crystallization system incorporates a rectangular stage with multiple sprockets and linear transfer paths, allowing for increased transfer path length without elongating the stage, improved heating section placement, and the use of a core to prevent neck deformation, along with detection and resupply mechanisms to maintain high positional accuracy and prevent supply failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the neck diameter of the molded article is increased to produce wide-mouth containers, then the ease of removing contents is improved, but the number of molded articles that can be disposed in the transfer path decreases
Solution Approach 1:
The patent transitions from a linear transfer path to a rectangular stage with multiple linear transfer paths arranged in parallel. This dimensional change allows multiple wide-mouth preforms to be processed simultaneously, increasing the quantity of molded articles that can be disposed in the transfer path while maintaining adequate heating section placement space.
2Quantity of substance
If the length of the long side of the stage is increased to accommodate more molded articles, then the number of molded articles that can be disposed increases, but the system becomes elongated and difficult to design layout
Solution Approach 1:
The patent employs a rectangular stage configuration with multiple linear transfer paths arranged parallel to the long side, utilizing both the length and width dimensions of the stage. This allows the system to accommodate more molded articles without excessively elongating the stage in one direction, thereby simplifying factory layout design while increasing capacity.
Solution Approach 2:
The transfer path is divided into multiple linear sections (first, second, third, and fourth linear transfer paths) that can be independently configured. This segmentation allows flexible arrangement of heating sections along different paths, optimizing space utilization and simplifying system layout while accommodating multiple wide-mouth preforms.
3Quantity of substance
If the distance between drive sprocket and driven sprocket is increased to accommodate longer transfer path, then more molded articles can be processed, but deflection of the endless member increases
Solution Approach 1:
The transfer path is segmented into multiple linear sections with sprockets positioned at strategic points along each section. This segmentation breaks the long transfer path into manageable segments, reducing the distance between adjacent sprockets and minimizing chain deflection while still accommodating multiple wide-mouth preforms through the rectangular stage configuration.
4Productivity
If the transfer speed is increased to improve throughput, then the productivity increases, but the heating section placement space decreases
Solution Approach 1:
The patent utilizes a rectangular stage with multiple linear transfer paths that extend along the long side. This configuration increases the total available heating section placement space by distributing heating sections across multiple parallel paths rather than requiring a single long linear path, thereby allowing higher transfer speeds while maintaining adequate heating space.
Solution Approach 2:
Heating sections are distributed across multiple linear transfer paths (first, second, third, and fourth paths) rather than concentrated in a single location. This segmentation of heating zones allows the system to maintain sufficient heating space while increasing overall transfer speed and throughput.
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 configuration enhances throughput by allowing faster transfer speeds, reduces chain deflection, and maintains system compactness, enabling efficient processing of wide-mouth containers with improved heat management and reduced deformation risks.
Implementation Method 1
a plurality of heating sections which heat the neck of the molded article
Implementation Method 2
heat the neck of the molded article
Implementation Method 3
a cooling section which cools the neck of the molded article
Implementation Method 4
inserting a core into the neck of the molded article
Data Source
Figure 1
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AI summary
A neck crystallization system includes a rectangular stage (20) that has long sides and short sides in a plan view, a plurality of sprockets (30 to 34) that are disposed on the stage, and an endless member (35) that is horizontally fitted around the plurality of sprockets. A transfer path (40) that is formed in an area in which the endless member is disposed, includes first to fourth linear transfer paths (41 to 44), the first to fourth linear transfer paths being parallel to each other, and extending in a direction along the long sides, the transfer directions of two transfer paths that are adjacent to each other in a direction along the short sides being opposite to each other. A plurality of heating sections (50) that are provided along at least the first to third linear transfer paths, and heat the neck of a molded article, a cooling section (60) that is disposed along at least the fourth linear transfer path, and cools the neck of the molded article, a molded article supply section (70) that supplies the molded article at a position on the upstream side of the plurality of heating sections, and a molded article removal section (80) that removes the molded article at a position between the cooling section and the molded article supply section, are provided along the transfer path (40) in which a plurality of transfer members (100) that respectively support the molded article are transferred.