Preform Distributor Deflecting Bulk Plastic Preforms
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Solution Overview
Problem
Existing methods for bulk storage of plastic preforms in containers result in low packing density due to inefficient use of storage volume, with previous solutions requiring complex and costly equipment such as shakers or lubricant applicators, or specialized equipment for ordered stacking.
Innovation Solution
A preform distributor is positioned above the open container's filling opening, deflecting preforms unevenly to distribute them evenly inside, preventing the formation of a central dome or pyramid and increasing the number of preforms per unit volume without the need for expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If preforms are dropped in bulk into an open container, then the storage process is simple and fast, but the packing density is low due to poor use of storage volume
Solution Approach 1:
The distributor divides the container's top opening into multiple zones using radial baffle elements, directing preforms into different spatial regions. This segmentation prevents the formation of a single large dome and improves volume utilization by distributing preforms more evenly throughout the container cross-section.
Solution Approach 2:
The distributor creates non-uniform local conditions at the container opening by using baffles of varying heights and positions. This local differentiation in the distribution pattern ensures that preforms are directed to specific areas, preventing dome formation at the center while maintaining high packing density overall.
2Quantity of substance
If a shaker apparatus is used to rearrange preforms, then packing density is improved, but the equipment becomes complex and expensive
Solution Approach 1:
The distributor performs the distribution function before preforms enter the container, creating an even initial arrangement. This preliminary action eliminates the need for subsequent shaking or rearrangement equipment, as the preforms are already optimally positioned for high-density packing upon entry.
Solution Approach 2:
The distribution function is extracted from the container system and implemented as a separate, simple distributor component at the opening. This separates the distribution function from complex shaking mechanisms, achieving improved packing density through a simple, dedicated distribution structure rather than complex post-filling rearrangement equipment.
3Quantity of substance
If lubricant is applied to preforms, then packing density is improved, but the equipment becomes complex and expensive and the preform surface becomes soiled
Solution Approach 1:
The distributor uses the preforms' own weight and the baffle structures to achieve even distribution and high packing density. No external lubricant or complex application equipment is needed; the system serves itself by utilizing gravitational flow and geometric distribution to accomplish the packing objective.
4Quantity of substance
If preforms are stacked in ordered manner, then packing density is improved, but special complex and expensive equipment is required
Solution Approach 1:
The complex mechanical stacking system is replaced by a simple passive distributor structure that uses gravitational flow and baffle geometry to achieve even distribution. The distributor substitutes complex active mechanical manipulation with a simple geometric arrangement that passively directs preforms into optimal positions.
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 significantly increases the packing density of preforms within the container by ensuring even distribution without the use of costly equipment, allowing for more efficient storage and transport.
Implementation Method 1
The preforms are inserted from above, dropping under gravity into the inside of the open container
Data Source
Figure 1~3
Figure 2
Figure 4~5
AI summary
A preform distributor (3) is provided above an open container (2) for improving the drop loading of the container (2) with preforms (P) in bulk,. Said distributor comprises a central opening (32), at least two lateral openings (33a ; 33b), and deflecting means (31) for deflecting preforms that are dropped above said deflecting means (31) into the lateral openings (33a ; 33b). The central opening (32) and each lateral opening (33a, 33b) are designed for enabling preforms to pass trough the distributor.