Intermittent Resin Feeding Mechanism for Compact Press Forming
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Solution Overview
Problem
Conventional fixed type press forming machines face challenges in increasing production capability due to bulky apparatus design caused by large distances between resin holders and cutters, leading to low productivity and practicality issues.
Innovation Solution
The system employs intermittently feeding devices that vary the moving speed of transfer units to align resin holders in a compact configuration, allowing for continuous and successive feeding of molten resin to metal molds, reducing the pitch between resin holders and enabling a smaller apparatus size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of metal molds is increased in a fixed type press forming machine, then the production capability should increase, but the distance between the extrusion port and metal molds increases causing the apparatus to become bulky
Solution Approach 1:
The patent applies dynamics by making the resin holder movable instead of fixed. The resin holder moves in the radial direction to convey molten resin to multiple metal molds at different positions, enabling the system to adapt to increased mold counts without proportionally increasing the apparatus size. This dynamic positioning allows compact arrangement while maintaining productivity.
Solution Approach 2:
The patent introduces radial movement as an additional dimension for resin conveyance. Instead of only arranging molds linearly along the extrusion direction, the resin holder moves radially outward to reach molds arranged in a circular pattern, effectively utilizing two-dimensional space to reduce the linear footprint of the apparatus.
2Productivity
If the cutting speed of the cutter is increased to cut more resin drops per minute, then the production capability increases, but the pitch between resin holders becomes very small making the apparatus bulky
Solution Approach 1:
The resin holder is designed to move dynamically with variable speed. During the resin receiving phase, it moves slowly to allow proper filling, then accelerates during conveyance to metal molds. This dynamic speed variation allows maintaining adequate pitch between holders while achieving high cutting speeds, resolving the contradiction between productivity and compactness.
Solution Approach 2:
The resin holder operates in periodic cycles: receiving molten resin slowly, then conveying it quickly to the next mold position. This periodic alternation between slow receiving and fast conveyance allows high overall productivity while maintaining sufficient space between holders during the critical receiving phase.
3Ease of operation
If the resin holder moves at constant speed, then the operation is simple, but the pitch between resin holders becomes large causing bulky apparatus design
Solution Approach 1:
The system transitions from constant speed operation to dynamic variable speed operation. The resin holder accelerates and decelerates at different phases of its cycle, allowing compact pitch between holders while maintaining ease of operation through automated speed control. This resolves the contradiction by making speed variable rather than constant.
Solution Approach 2:
The patent changes the speed parameter of the resin holder from constant to variable. By adjusting the speed parameter dynamically during different operational phases (receiving vs. conveying), the system achieves compact dimensions while maintaining operational simplicity through automated parameter control.
Data Source
AI summary
To efficiently feed a molten resin to the resin holders. An intermittently feeding device works to intermittently feed a transfer unit equipped with resin holders, and has a cam supported by a motor via a support. The cam is rotated by the motor. A cam follower of a moving block meshes with the screw of the cam, and the moving block moves along a support rail accompanying the turn of the cam. The motor rotates at a constant speed, and the transfer unit 3 is fed intermittently depending on the shapes of the cam and of the cam follower.