Piston Suction for Mold Decoration Positioning
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Solution Overview
Problem
Existing methods for positioning decorations in thermoforming molds are limited, as they often result in poorly positioned decorations, especially for labels, due to lack of control over orientation and height, leading to weakened zones and unsuitable supports for commercial use.
Innovation Solution
A method and device that wind a strip of decorations around a piston, using drive rollers and a counter-blade with suction means to ensure precise positioning at the desired height within the mold, allowing for both strip and label decorations to be accurately placed, eliminating the need for mechanical retention edges and enabling use in molds of any structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circumferential edge is added to the mold to prevent decoration sliding, then positioning reliability is improved, but the support structure is weakened creating recesses
Solution Approach 1:
The patent uses suction means (vacuum system) to hold the decoration on the piston and in the mold cell, replacing the need for mechanical circumferential edges. The suction creates negative pressure that securely positions the decoration without adding physical structures that would weaken the support.
Solution Approach 2:
The invention replaces the mechanical edge-based retention system with a pneumatic suction system. Instead of using physical circumferential edges to prevent sliding, the patent uses controlled vacuum pressure to hold the decoration in place during positioning and thermoforming.
2Ease of manufacture
If decorations are introduced using conventional piston methods, then the process is simple, but label decorations become misoriented or twisted during insertion
Solution Approach 1:
The suction means are activated on the piston to hold the label decoration firmly in place during the insertion process. This pneumatic holding prevents the label from twisting or becoming misoriented as the piston moves into the mold cell, while still maintaining process simplicity.
Solution Approach 2:
The decoration is pre-positioned on the piston using suction means before the piston enters the mold cell. This preliminary securing action ensures the decoration maintains its correct orientation throughout the insertion process, preventing misorientation issues.
3Strength
If a two-part mold is used to avoid circumferential edges, then support strength is maintained, but the device complexity and production time increase
Solution Approach 1:
The suction system allows the use of simplified one-part molds without circumferential edges while maintaining decoration retention. The pneumatic holding force replaces the need for complex two-part mold structures, reducing device complexity and enabling faster production cycles.
Solution Approach 2:
The suction means serve multiple functions: holding the decoration on the piston during insertion, securing it in the mold cell during thermoforming, and releasing it after forming. This multi-functionality eliminates the need for separate mechanical retention structures.
4Manufacturing precision
If suction means are used to hold decoration on piston, then positioning precision is improved, but energy consumption increases
Solution Approach 1:
The suction means are activated periodically - turned on before and during decoration insertion, then deactivated after positioning is complete. This intermittent operation provides precise positioning when needed while minimizing energy consumption during non-critical phases of the cycle.
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
Ensures correct and consistent decoration positioning at any height, preventing twisting and ensuring high-quality external appearances of supports, suitable for both strip and label decorations, even in simplified molds without mechanical retention.
Implementation Method 1
The piston is provided with suction means for holding the decoration on the piston and means for holding the decoration in the cavity of the mold
Data Source
AI summary
The invention relates to a method of positioning a decoration (20, 21) in a cavity (50, 60) of a mold (5, 6), comprising the following steps: - providing a strip (2) of decoration, - wrapping a decoration (20, 21) around at least part of a piston (16, 3), located above said cavity in a high position, - activating means (161, 162; 311, 312, 313) to hold the decoration on the piston, - introducing the piston and the decoration into a cavity (50, 60) of the mold (5, 6), by moving the piston in translation along its longitudinal axis to a low position, - activating means (51, 61) at the level of the cavity (5, 6) to ensure that the decoration (20, 21) is held in the mold and deactivating the means for holding the decoration on the piston, and - remove the piston from the mold cavity.