Parallel Shape Forming System With Integrated Conveyance Plates
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Solution Overview
Problem
The existing shape forming systems require complex and expensive conveyance units between heating, pressing, and cooling units, leading to increased size, gas consumption, and operational costs due to the need for large isolation chambers to maintain a non-oxidative atmosphere.
Innovation Solution
A shape forming system with mold assemblies, heating, pressing, and cooling units arranged in parallel within an isolation chamber, where conveyance is achieved by moving mold assemblies on plates with coupling pins, allowing for sequential processing and reducing the need for extensive conveyance units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyance units are provided between each of the heating, pressing, and cooling units to move mold assemblies, then the shape forming cycle is shortened by simultaneous processing of multiple materials, but the system becomes complicated and expensive
Solution Approach 1:
The patent combines the conveyance function with the processing units by integrating conveyance plates into the heating, pressing, and cooling units themselves. The mold assemblies are moved along a continuous path using the processing units' own plates rather than separate conveyance units, merging transportation and processing functions into a single integrated system.
Solution Approach 2:
The heating units, pressing units, and cooling units serve dual purposes: they perform their respective thermal processing functions while simultaneously acting as conveyance mechanisms. The plates in each unit both process the mold assemblies and transport them along the production line, eliminating the need for dedicated conveyance equipment.
2Reliability
If conveyance units and large isolation chamber are used to maintain non-oxidative atmosphere, then the materials can be processed without oxidation, but the footprint and gas consumption increase
Solution Approach 1:
The isolation chamber is divided into multiple separate sections, each corresponding to a specific processing unit (heating, pressing, cooling). Each section maintains the non-oxidative atmosphere independently, allowing for a more compact overall design while ensuring protected processing throughout the entire mold assembly journey.
Solution Approach 2:
The plates serving as conveyance surfaces also function as intermediaries that maintain the non-oxidative environment. The plates are positioned within the isolation chamber sections to provide both mechanical support for the mold assemblies and a barrier that helps maintain the protective atmosphere during transfer between processing stages.
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 efficiency, reduces system complexity and size, lowers gas usage, and decreases operational costs by enabling high-efficiency processing and uniform heating with infrared lamps, while maintaining a non-oxidative atmosphere.
Implementation Method 1
heating unit configured to heat the mold assembly to thereby subject the to-be-formed material to a heating treatment
Implementation Method 2
pressing unit configured to apply pressure to the mold assembly to thereby subject the to-be-formed material to a shape forming treatment
Implementation Method 3
cooling unit configured to cool the mold assembly after the shape forming treatment to thereby subject a shaped product to a cooling treatment
Data Source
AI summary
A shape forming system according to one embodiment includes a mold assemblies; a heating unit; a pressing unit; a cooling unit; an isolation chamber configured to accommodate therein the heating unit, the pressing unit, and the cooling unit arranged in parallel with each other; and a conveyance unit configured to move the plurality of mold assemblies each of which is arranged on a plate provided in each of the heating unit, the pressing unit, and the cooling unit to thereby convey the mold assemblies in sequence.