Plastic Container Molding with a Moving Extrusion Unit
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Solution Overview
Problem
Existing devices for producing plastic containers face inefficiencies due to complex kinematic movements, high energy consumption, and difficulty integrating into existing production lines, leading to increased waste and susceptibility to failure.
Innovation Solution
A device with a stationary molding tool and continuous extrusion process, where the extrusion unit moves relative to the molding tool, eliminating the need for complex kinematic movements and allowing for precise alignment, reduced energy consumption, and improved integration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the molding tool is moved back and forth in the extrusion direction to accommodate continuous extrusion, then the production continuity is improved, but the device complexity and energy consumption increase due to complex kinematic movements and port relocation
Solution Approach 1:
Instead of moving the molding tool in the extrusion direction to accommodate continuous extrusion, the invention inverts the approach by making the extrusion unit movable relative to the stationary molding tool. The molding tool remains fixed in all positions, while the extrusion unit moves to feed plastic hose into the receiving position, thereby maintaining production continuity without complex kinematic movements of the molding tool
Solution Approach 2:
The invention extracts the mobility requirement from the molding tool and assigns it to the extrusion unit instead. The molding tool is taken out of the moving system and made stationary, while the extrusion unit becomes the movable component that feeds material to the stationary mold, simplifying the overall kinematic complexity
2Productivity
If the molding tool is made heavy with multiple cavities for high production output, then the productivity is improved, but the manufacturing precision deteriorates due to difficulty in aligning mold halves
Solution Approach 1:
The invention inverts the traditional approach by making the molding tool stationary rather than movable. This stationary arrangement allows for precise alignment of mold halves even when the tool is heavy and contains multiple cavities, as the alignment is established once and maintained throughout the production process without movement-induced misalignment
3Adaptability or versatility
If the extrusion unit and molding tool both move in complex patterns, then the process flexibility is improved, but the reliability deteriorates due to increased susceptibility to failure
Solution Approach 1:
The invention extracts the mobility function from the molding tool and concentrates it in the extrusion unit. This separation reduces the number of moving parts in the molding system, thereby increasing reliability while maintaining process flexibility through the movable extrusion unit that can feed material to the stationary mold
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
The solution enhances production efficiency, reduces waste, lowers energy consumption, and improves integration into existing lines, while ensuring a sterile environment and stable operation.
Implementation Method 1
an extrusion unit (12), which can be used to feed at least one plastic hose (14) into the receiving position (22)
Implementation Method 2
a molding device (16) having individual molding tools (18), which can be moved repeatedly relative to one another from an open receiving position (22) into a molding sealing position
Data Source
AI summary
A device for producing plastic containers (10) by a molding, filling and sealing process includes a molding device (16) having individual molding tools (18), which can be moved repeatedly relative to one another from an open receiving position into a molding sealing position, and includes an extrusion unit (12), which can be used to insert at least one extruded plastic hose (14) into the open receiving position of the molding tools (18). A traversing unit (20) moves the extrusion unit (12) in conjunction with each extruded plastic hose (14) in opposite directions with respect to the molding device (16), which is stationary in every position of the molding tools (18).