Preform Manufacturing Device Integrating Decontamination and Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing mechanical recycle method for manufacturing preforms from thermoplastic resin flakes is inefficient due to multiple steps required for decontamination, crystallization, drying, and injection molding, which hampers productivity and quality.
Innovation Solution
Integration of a decontamination apparatus with an injection molding apparatus, including a filter and a gear pump, to directly melt and mold the decontaminated resin flakes, reducing the number of processing steps and enhancing control over resin flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple processing steps (crystallization, drying, injection molding) are used to manufacture preforms from resin flakes, then the quality and purity of preforms can be maintained, but the productivity and manufacturing efficiency deteriorate due to the complexity and time consumption of multiple steps
Solution Approach 1:
The patent combines multiple processing functions (decontamination, melting, filtering, and injection molding) into an integrated system where the decontamination apparatus directly connects to the injection molding apparatus, eliminating intermediate steps such as separate crystallization and drying processes. This merging of functions reduces the number of processing steps while maintaining preform quality.
Solution Approach 2:
The injection molding apparatus is designed to perform multiple functions: it receives decontaminated resin directly from the decontamination apparatus, melts the resin, filters contaminants through an integrated filter, and molds the preforms. This multi-functionality eliminates the need for separate dedicated equipment for each processing step.
2Manufacturing precision
If multiple processing steps including high-temperature crystallization and drying are implemented, then the quality of crystalized resin can be improved, but the manufacturing time and energy consumption increase
Solution Approach 1:
The patent establishes a continuous processing flow where decontaminated resin is immediately melted and molded without interruption for separate crystallization and drying steps. The resin undergoes continuous transformation from solid flake to molded preform through the integrated system, eliminating idle time between processing stages.
Solution Approach 2:
The system controls resin temperature and processing parameters dynamically within the injection molding apparatus, achieving the necessary resin quality and crystallization directly during the molding process rather than through separate high-temperature treatment steps, thereby reducing total processing time.
3Reliability
If a filter is added to remove foreign matter from melted resin, then the purity of preforms is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The filter is integrated into the injection molding apparatus as an internal component rather than being a separate external device. This merging of the filtering function into the existing molding equipment achieves resin purification without adding significant structural complexity or requiring additional standalone apparatus.
4Manufacturing precision
If a gear pump is added to supply melted resin consistently to the injection molding apparatus, then the manufacturing precision and resin flow control are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The gear pump is integrated as an internal component of the injection molding apparatus, merging the resin transport function with the molding equipment. This integration provides precise resin flow control and consistent supply to the molding cavity without requiring a separate external pumping system, thereby minimizing additional structural complexity.
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 integration significantly enhances productivity and quality by reducing the number of processing steps, minimizing thermal stress on the resin, and ensuring consistent resin supply, thereby improving the efficiency of preform manufacturing.
Implementation Method 1
foreign matter in the resin is removed by passing the resin through a filter
Implementation Method 2
a gear pump is disposed between the filter and the injection molding apparatus
Implementation Method 3
the extruded amorphous resin is heated up to high temperature (about 220 degrees Celsius) and is crystallized
Implementation Method 4
the extruded amorphous resin is heated up to high temperature (about 220 degrees Celsius) and is crystallized
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A preform manufacturing device for manufacturing a preform from thermoplastic resin flakes, comprises a decontamination apparatus removing contaminants in the thermoplastic resin flakes, and an injection molding apparatus injecting and molding the thermoplastic resin supplied from the decontamination apparatus.