Plastic Container Blow Molding with Compact Multi-Station Carriers
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Solution Overview
Problem
Existing blow molding systems for forming plastic preforms into containers require a large footprint and high costs due to the limited number of forming stations on a transport carrier, especially when operated in a cleanroom environment, leading to increased space and sterilization requirements.
Innovation Solution
The system reduces the transport carrier diameter and increases the number of forming stations, using a rotatable carrier with multiple blow molding devices and a compact cleanroom design, allowing for a smaller footprint and cost-effective operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the transport carrier diameter is reduced to decrease system footprint, then space requirement and cost are reduced, but the number of forming stations that can be arranged is limited
Solution Approach 1:
The patent transitions from a horizontal arrangement of forming stations on a large-diameter transport carrier to a vertical arrangement within a cleanroom. By utilizing the vertical dimension and arranging forming stations along a compact transport carrier's circumference inside the cleanroom, the system achieves high productivity without requiring large horizontal footprint.
Solution Approach 2:
The transport carrier with multiple forming stations is arranged within the cleanroom boundaries. The compact carrier design allows forming stations to be nested efficiently within the limited cleanroom space, maximizing the use of available volume rather than spreading out horizontally.
2Productivity
If more forming stations are arranged on the transport carrier to increase productivity, then output is improved, but the transport carrier diameter and system footprint increase
Solution Approach 1:
Instead of increasing the horizontal diameter of the transport carrier to accommodate more forming stations, the patent utilizes the vertical dimension by arranging the transport carrier and forming stations within the cleanroom's vertical space. This allows high productivity without proportionally increasing the horizontal footprint.
3Reliability
If the transport carrier is arranged within a cleanroom to maintain sterile conditions, then product contamination is prevented, but the required cleanroom size and sterilization costs increase
Solution Approach 1:
The transport carrier with forming stations is nested within the cleanroom boundaries. By concentrating the forming stations on a compact carrier within the cleanroom volume, the patent minimizes the cleanroom size required while maintaining sterile conditions for all forming operations.
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 enables a more efficient use of space and resources, reducing system size and costs while maintaining sterile conditions for the forming process.
Implementation Method 1
blow-molding devices with at least two blow-molding side parts and a bottom part, which form a hollow space inside which the plastic preforms can be formed into the plastic containers by applying a flowable medium
Data Source
AI summary
An apparatus for forming plastic preforms into plastic containers, having a transport device which transports the plastic preforms along a predetermined transport path. The transport device has a movable and in particular rotatable transport carrier on which a plurality of forming stations is arranged. The forming stations each having blow molding devices with at least two blow mold side parts and a bottom part which form a hollow space inside which the plastic preforms are formed into the plastic containers by applying a flowable medium. The forming stations each having application devices for applying the flowable medium to the plastic preforms. A diameter of the transport carrier is smaller than 2 m, and 4-16 forming stations are arranged on the transport carrier or a diameter of the transport carrier is smaller than 3 m, and 17 to 35 forming stations are arranged on the transport carrier.