Swirl Flow Preform Forming for Radial Expansion
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Solution Overview
Problem
In hydroforming processes, the radial expansion of preforms is often insufficient, leading to suboptimal bi-orientation ratios and container shapes, as the liquid injection primarily targets the bottom of the preform, causing uneven expansion and cooling issues before the upper part is fully formed.
Innovation Solution
A forming station with a swirl imparting element in the injection nozzle creates a centrifugal force through a swirling flow, promoting radial expansion of the preform by rotating the pressurized liquid around the preform axis, ensuring even expansion and optimizing the bi-orientation ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If liquid is injected vertically into the preform bottom-first, then the bottom part is first expanded, but the upper part of the container becomes insufficiently expanded due to cooling during liquid injection
Solution Approach 1:
The patent introduces a swirl flow component to the otherwise vertical liquid injection. By adding rotational motion around the preform axis, the liquid flow transitions from purely axial to a combination of axial and radial components, enabling simultaneous expansion of both bottom and upper parts of the preform.
Solution Approach 2:
The patent modifies the liquid flow parameters by creating a swirling flow pattern. This changes the flow direction and distribution, allowing the liquid to impact the preform walls at multiple locations simultaneously rather than just at the bottom, thereby improving radial expansion uniformity.
2Strength
If liquid is injected at low temperature, then the preform material remains stable, but the radial expansion of the preform is insufficient
Solution Approach 1:
The swirl flow creates a rotational mechanical action that applies centrifugal forces to the preform walls. This dynamic flow pattern enhances radial expansion without requiring temperature increase, as the rotational motion itself provides the necessary expanding force.
Solution Approach 2:
The patent utilizes hydraulic principles by creating a swirling liquid flow that generates centrifugal force. The rotational hydraulic flow acts on the preform walls to promote radial expansion, effectively using fluid dynamics to achieve shaping without thermal assistance.
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 method enhances the radial expansion of the preform, resulting in a more satisfactory container shape and improved bi-orientation ratio, with the liquid impacting the preform walls evenly across its height, preventing material cooling and ensuring efficient filling and forming.
Implementation Method 1
a swirl imparting element of the injection nozzle extending in the injection flow imparts a swirl flow on the pressurized liquid between the pressurized liquid source and the outlet such that the pressurized liquid applies a centrifugal force on the wall of the preform during forming and filling of the preform
Data Source
AI summary
A method for simultaneously forming and filling a container by injecting a pressurized liquid in a preform. The method includes placing the preform in a mold and injecting the pressurized liquid into the preform such that the liquid expands the preform and urges the wall of the preform against the wall of the molding cavity forming the preform into a container and the container is filled with liquid. A swirl imparting element extends in the injection flow and imparts a swirl flow on the pressurized liquid such that the pressurized liquid applies a centrifugal force on the wall of the preform during forming and filling of the preform, thereby promoting a radial expansion of the preform in radial planes substantially perpendicular to the preform axis.