Spherical Toilet Block Forming With Pitch-Differential Screws
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Solution Overview
Problem
Conventional manufacturing processes for spherical toilet blocks result in a high proportion of poorly formed products and require significant amounts of lubricant, leading to inefficiencies and resource wastage.
Innovation Solution
A continuous process using a ball rolling machine with forming screws that rotate in the same direction and have a pitch difference, allowing direct shaping of the extruded mixture into spherical bodies without cutting, thereby reducing defects and lubricant usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional extrusion and cutting processes are used to produce spherical toilet blocks, then the manufacturing process is simple and straightforward, but the rate of poorly formed products is high and lubricant consumption is significant
Solution Approach 1:
The invention applies preliminary action by pre-forming the mixture into a continuous strand with controlled dimensions before spherical formation. The extrusion step creates a uniformly sized feedstock that is optimally prepared for the subsequent ball-rolling process, reducing variability and improving formation quality while maintaining continuous production.
Solution Approach 2:
The invention implements continuity of useful action by eliminating the cutting step and transitioning from discrete batch processing to continuous spherical formation. The ball-rolling machine continuously transforms the extruded strand into spherical toilet blocks without interruption, maintaining steady production flow and reducing defects associated with start-stop operations.
2Loss of substance
If conventional cutting and lubrication steps are included in the process, then the production workflow is established, but material waste and lubricant consumption increase
Solution Approach 1:
The invention applies the taking out principle by removing the cutting step and associated lubrication operations from the manufacturing process. By using continuous spherical formation directly on the extruded strand, the process eliminates the need for additional lubricant application, reducing both material waste and process complexity.
Solution Approach 2:
The ball-rolling machine performs self-service by simultaneously completing both the spherical formation and surface preparation in a single integrated operation. The mechanical action of rolling automatically provides sufficient surface treatment without requiring separate lubrication steps, allowing the process to serve its own needs without additional auxiliary operations.
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 process significantly reduces the rate of poorly formed toilet blocks and minimizes lubricant consumption, resulting in more efficient and economical production with fewer returns.
Implementation Method 1
the at least two forming screws are installed in the ball rolling machine in such a way that they run essentially parallel to one another and with a pitch difference from one another
Implementation Method 2
Deforming the mixture fed in according to step b) into spherical bodies by feeding the mixture of toilet block ingredients to the at least two rotating forming screws
Data Source
Figure 1
Figure 2a~2b
AI summary
The present invention relates to a continuous process for producing spherical toilet blocks and to toilet blocks obtained by this process.