Parison Transfer Molding for Precise BFS Container Production
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Solution Overview
Problem
The existing blow molding, filling, and sealing processes are inefficient due to the need for frequent movement of heavy molding tools and the lack of precise alignment, which increases energy consumption and complicates the production process.
Innovation Solution
A method involving a stationary molding tool and a gripper device that transports a heat-softened parison to a fixed molding position, allowing for precise alignment and additional processing steps like calibration and surface treatment, without the need for tool movement, and uses a gripper device to hold the parison at two points for stable transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the molding tool is moved from the extrusion device to the sealing station during every process run, then the production process can be completed, but the energy consumption increases and the process becomes more complex
Solution Approach 1:
Instead of moving the molding tool between extrusion and sealing stations, the invention inverts the approach by keeping the molding tool stationary and moving only the parison (container precursor) through fixed positioning stations. This eliminates the energy-intensive movement of heavy molding tools while completing the same production process.
Solution Approach 2:
The production process is segmented into distinct stationary stations (extrusion station, positioning station, sealing station) with the molding tool remaining fixed at one location. The parison is transported between these stations, allowing each operation to be performed at a dedicated fixed position rather than moving the entire molding tool assembly.
2Productivity
If the molding tool is moved from the extrusion device to the sealing station during every process run, then the production process can be completed, but the device complexity increases
Solution Approach 1:
The invention simplifies device complexity by inverting the conventional approach: instead of moving the complex molding tool assembly, a simpler parison transfer mechanism is used to move only the container precursor between fixed stations, reducing mechanical complexity.
Solution Approach 2:
The production system is divided into separate functional stations (extrusion, positioning, sealing) that remain stationary. This segmentation eliminates the need for complex moving connections and utilities in the molding tool, as each station has its own fixed infrastructure.
3Productivity
If the molding tool is moved from the extrusion device to the sealing station during every process run, then the production process can be completed, but the alignment precision decreases
Solution Approach 1:
Rather than moving the molding tool and risking alignment errors, the invention fixes the molding tool in place and uses a controlled parison transfer system with precise positioning mechanisms to deliver the container precursor to the correct location, improving alignment precision.
4Ease of manufacture
If the hose is extruded directly into an open mold, then the process is simpler, but the parison is less accessible for additional processing steps
Solution Approach 1:
The process is segmented into extrusion of the parison as a free-standing component, followed by separate positioning and processing steps. This allows the parison to be independently manipulated and treated (e.g., surface treatment, calibration) before final molding, enhancing versatility while maintaining process simplicity through modular station design.
Solution Approach 2:
Additional processing steps such as surface treatment or calibration can be performed on the parison in advance at the positioning station before the parison is transferred to the sealing station for final molding. This preliminary action allows modifications to be made while the parison is still accessible and heat-softened.
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 approach reduces energy consumption, simplifies the process, enables precise control over parison dimensions and surface properties, and allows for efficient production of lightweight containers without deformation, even for small volumes, enhancing the overall efficiency and quality of the container production.
Implementation Method 1
extruding a hose by an extrusion device using supporting gas in the vertical extrusion direction
Implementation Method 2
forming the parison into a container by applying a pressure gradient to the heat-softened parison
Implementation Method 3
Sealing the mold welds the hose at its leading end
Data Source
AI summary
A method for producing at least one molded, filled and sealed container product (10) includes at least the method steps of: extruding a hose (32) by an extrusion device (12) using supporting gas in vertical extrusion direction in a preforming position; sealing the hose (32) at its lower end and cutting it at its upper open end; cutting the parison (22) to length; transporting the cut parison by a gripper device (20) in linear transport direction transverse to the extrusion direction from the preforming position into an opened molding tool (18); transferring the parison (22) into the opened molding tool (18) by the gripper device (20) in a main forming position; sealing the molding tool (18) for further forming of the parison (22) by a pressure gradient; filling and sealing the parison (22); and returning the gripper device (20) to the preforming position for a repeated sequence of the above method steps.