Segmented Undercut Pot Mold Design for Reduced Material Waste
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Solution Overview
Problem
Existing undercut pot production lines are expensive and complex, with significant material loss due to the need for specialized equipment and processes, limiting their versatility and efficiency.
Innovation Solution
A mold and machine design that reduces the opening distance between sub-molds, allowing for conventional sheet material supply without pre-cutting, featuring a non-symmetrical undercut shape that minimizes material waste and adapts to conventional production line tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional opening molds are used to extract undercut pots, then the pots can be demolded, but the longitudinal footprint of the mold increases significantly requiring large spacing between mold rows
Solution Approach 1:
The opening mold is divided into two independent halves that can move relative to each other along the demolding direction. This segmentation allows each half to be positioned independently, reducing the overall longitudinal footprint while maintaining the ability to fully open for demolding undercut pots.
Solution Approach 2:
The mold design transitions from a single rigid structure to a multi-component system with movement in multiple dimensions. The two halves can slide past each other horizontally while maintaining vertical alignment, utilizing dimensional freedom to reduce longitudinal space requirements.
2Ease of operation
If large spacing is provided between rows of opening molds to accommodate full opening, then material loss between rows increases significantly
Solution Approach 1:
By segmenting the mold into two compact halves that open laterally rather than requiring large longitudinal separation, the spacing between mold rows is minimized. This reduces the amount of forming material that must be wasted in the gaps between rows while preserving full demolding capability.
3Shape
If specialized equipment and processes are used for undercut pot production, then the pots can be manufactured with undercut shape, but production line complexity and cost increase significantly
Solution Approach 1:
The opening mold design with two movable halves serves multiple functions: it can form and demold undercut pots, accommodate various pot geometries, and integrate with conventional production line equipment. This universal design eliminates the need for specialized complex equipment while maintaining undercut shape capability.
Solution Approach 2:
Instead of using complex specialized equipment to create undercut shapes, the invention inverts the approach by using a simple segmented mold design where the two halves slide past each other. This inverted approach achieves the same undercut shape capability with much simpler equipment.
4Loss of substance
If the opening distance between sub-molds is reduced, then material loss is decreased, but the ability to demold undercut pots may be compromised
Solution Approach 1:
The mold is segmented into two halves that can open laterally with minimal separation distance. This segmentation allows the mold to maintain a compact footprint while still providing sufficient opening for demolding, as each half can be positioned independently to accommodate the undercut geometry without requiring large overall opening distance.
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
Significantly reduces production costs and complexity, maintains aesthetic appeal, and enables efficient manufacturing of undercut pots with reduced material loss, making the production line more versatile and cost-effective.
Implementation Method 1
The sheet, wound around the reel, is unwound lengthwise, heated, and brought into contact with the upper surface of the molds to be shaped
Implementation Method 2
The shaped pot is then processed at various stations, equipped with means for dosing the pot contents, tools for welding a lid
Data Source
Figure 1A~1D
Figure 2A~2B
Figure 2C~3D
AI summary
An undercut pot comprising a bottom wall (5), a side wall (6) closed upon itself and connected to the bottom wall (5), and an opening providing access to the interior of the pot. The outer surface of the side wall of the pot has an asymmetrical undercut shape of revolution about the vertical direction (Z). The outer surface has at least one vertical molding plane (P) such that an undercut value of the pot at the respective lateral ends of the pot, with maximum lateral distance of the outer surface from the vertical molding plane (P), is less than a maximum undercut value of the pot on the circumference of the outer surface of the pot.