Parallel Valve Filter for Injection Molding Pressure Relief
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Solution Overview
Problem
Current injection-molding processes require significant energy and labor for purifying contaminated plastics, leading to high production downtimes and reduced productivity due to frequent filter cleaning and replacement, as contaminants often clog filter devices, necessitating frequent changes and assembly/disassembly.
Innovation Solution
A filter device with a valve element in a fluidically parallel arrangement to the filter element allows for rapid pressure relief, facilitating easier cleaning and replacement by preventing material flow during injection and allowing flow post-injection, and a plasticizing unit with a modular injection cylinder design for quick filter access and exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a filter device is used to purify contaminated plasticized material, then the purity of the material is improved, but the filter element clogs frequently requiring cleaning or replacement
Solution Approach 1:
The patent implements a dual filter element system where one filter element is in use while the other is prepared for replacement. When the active filter element becomes clogged, the system automatically switches to the standby filter element, allowing the clogged one to be replaced without stopping production. This resolves the contradiction by ensuring continuous purification capability while managing filter element lifecycle.
Solution Approach 2:
The system maintains a standby filter element that is pre-positioned and ready for immediate use before the active filter element fails. This preliminary preparation eliminates downtime associated with filter replacement, as the replacement filter is already in place and ready to be activated when needed.
2Manufacturing precision
If the filter device is cleaned or replaced frequently, then the purity of the material is maintained, but the productivity of the injection-molding machine decreases due to assembly and disassembly work
Solution Approach 1:
The dual filter element system allows one filter to be in use while the other is replaced, enabling filter maintenance without production interruption. This resolves the contradiction by decoupling filter replacement operations from production operations, maintaining both high purity standards and continuous productivity.
Solution Approach 2:
The system ensures continuous material purification by having a standby filter element ready to take over immediately when the active filter element is replaced. This maintains the uninterrupted flow of purified material through the injection-molding machine, preserving both purity and productivity simultaneously.
3Manufacturing precision
If the filter device is replaced frequently, then the purity of the material is maintained, but the downtime of the injection-molding machine increases
Solution Approach 1:
The patent employs a dual filter element configuration where a standby filter element is always available. When the active filter element reaches the end of its service life, the system can switch to the standby element without stopping the injection-molding process, eliminating replacement downtime while maintaining material purity.
Solution Approach 2:
The standby filter element is pre-positioned in the system before it is needed, allowing for immediate activation when the active filter element requires replacement. This preliminary preparation eliminates the time loss associated with retrieving and installing a new filter element during production.
4Power
If the filter element is under high pressure during injection process, then the material is properly injected, but the filter element cannot be cleaned or replaced easily
Solution Approach 1:
The dual filter element system allows the active filter to maintain high injection pressure while the standby filter is replaced in a separate maintenance operation. This decouples the high-pressure injection function from the filter replacement operation, maintaining both effective injection power and easy maintenance accessibility.
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 solution reduces downtime and increases productivity by simplifying filter cleaning and replacement, enhancing energy efficiency and enabling more efficient recycling and compounding applications, thus improving environmental sustainability.
Implementation Method 1
at least one valve element is provided, which is formed to prevent the plasticized material from flowing through the at least one filter element during an injection process in a closed position and to allow the plasticized material to flow through the at least one valve element in an open position, in order to make it possible to relieve the pressure on the at least one filter element after the injection process
Data Source
AI summary
Filter device for a molding machine with at least one filter element for filtering plasticized material, in particular plasticized plastic, wherein, in a fluidically parallel arrangement relative to the at least one filter element, at least one valve element is provided, which is formed to prevent the plasticized material from flowing through the at least one valve element during an injection process in a closed position and to allow the plasticized material to flow through the at least one valve element in an open position, in order to make it possible to relieve the pressure on the at least one filter element after the injection process.