Blow Moulding Spacer Layout for Thermoplastic Tank Component Insertion
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Solution Overview
Problem
Conventional thermoplastic tank manufacturing methods for vehicles face limitations in shaping internal components due to size and positioning constraints during the blow moulding process, leading to potential defects and material inefficiencies.
Innovation Solution
A blow moulding tool with a mould comprising moveable spacers and an insertion pin system that allows for the precise positioning and alignment of internal components within a closed tubular parison, enabling the creation of a smaller parison size while maintaining desired shape and volume, and incorporating multiple components simultaneously for increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a closed tubular parison is used for blow moulding, then the tank can be manufactured with internal components, but the internal component size and shape are limited due to insertion constraints
Solution Approach 1:
The internal component is inserted into the closed tubular parison before the blow moulding process begins. This preliminary insertion allows the component to be positioned within the parison walls without interfering with the subsequent expansion process, thereby enabling complex component shapes while maintaining manufacturing ease
Solution Approach 2:
The internal component is nested within the walls of the closed tubular parison, with the component positioned inside the parison structure before moulding. This nesting approach allows the component to be incorporated into the tank wall structure itself, enabling versatile component shapes while avoiding insertion constraints
2Reliability
If the internal component is made large or thick, then the component functionality is improved, but the closed tubular parison bulges or wraps causing improper tank shaping
Solution Approach 1:
The internal component is pre-positioned within the closed tubular parison walls before blow moulding occurs. This preliminary positioning ensures that even large or thick components do not cause bulging or wrapping during expansion, as they are already constrained within the parison structure, thereby maintaining both component functionality and tank shape accuracy
Solution Approach 2:
The parison walls are designed with varying local thicknesses and densities in different regions to accommodate internal components of different sizes and shapes. This local quality adjustment allows large or thick components to be incorporated without causing uniform bulging, maintaining overall tank shape precision while ensuring component functionality
3Volume of moving object
If the internal component is positioned close to the parison walls, then space utilization is improved, but uneven pressure during blow moulding causes defects
Solution Approach 1:
The internal component is segmented or designed with specific geometric features that allow it to be positioned close to the parison walls while maintaining adequate clearance. The component may be divided into sections or have varying cross-sections that optimize space utilization without creating pressure concentration points, thereby preventing moulding defects
Solution Approach 2:
The parison and component interfaces are designed with locally optimized properties, including variable wall thicknesses and surface characteristics, to ensure uniform pressure distribution even when components are positioned close to the walls. This local quality control allows maximum space utilization while preventing pressure-related defects
4Productivity
If conventional insertion methods are used, then the process is simple, but multiple components cannot be inserted simultaneously reducing production efficiency
Solution Approach 1:
Multiple internal components are pre-positioned within the closed tubular parison walls simultaneously before the blow moulding process begins. This preliminary multi-component insertion eliminates the need for sequential insertion operations, thereby significantly improving production efficiency while the integrated parison structure keeps the insertion system relatively simple
Solution Approach 2:
The insertion of multiple internal components is merged into a single simultaneous operation during the parison formation stage. Rather than inserting components one by one during or after moulding, all components are incorporated together into the parison structure at once, improving productivity while maintaining manageable system complexity through the unified process
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 approach reduces material usage, minimizes defects, and enhances production efficiency by allowing for easier insertion and alignment of components, resulting in cost-effective and sustainable thermoplastic fuel tank production with improved structural integrity.
Implementation Method 1
a blow moulding tool for manufacturing a thermoplastic tank... comprises: at least one insertion pin configured to position at least one component through an opening at a first distal end of a closed tubular parison
Data Source
Figure 1A~1B
Figure 1C~2A
Figure 2B~2C
AI summary
The invention relates to a blow moulding tool (100) for manufacturing a tank comprising: an insertion pin (102) configured to position a component (104) through an opening of a closed tubular parison (106); a mould; a first and a second mould portions (108, 110) each comprise a cavity (112, 113) with a movement member (114, 114', 115, 115') moving in a direction perpendicular to an extrusion direction of the closed tubular parison; a first and a second displaceable spacers (116, 118) arranged on a periphery of the cavity of the first mould portion and the second mould portion, respectively, and configured to move into three positions (open, partially-open and closed) on an axis perpendicular to the extrusion direction of the closed tubular parison; When the blow moulding tool is partially-open, the first and the second displaceable spacers are configured to receive a third displaceable spacer (120).