Thermoforming Carousel with Interchangeable Mold Dies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermoforming devices are limited in producing containers of different formats and materials at a high rate, as they require multiple devices for various formats and suffer from material shrinkage issues during cooling, leading to deformation and reduced manufacturing efficiency.
Innovation Solution
A device with a carousel system that allows for continuous manufacture of containers by thermoforming, enabling interchangeable mold dies and maintaining an air gap between the container and mold die during cooling to prevent shrinkage, thus allowing production of various formats and materials efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional thermoforming devices are used to produce containers of different formats, then multiple separate devices are required for each format, but this increases device complexity and reduces productivity
Solution Approach 1:
The patent implements a universal forming press that can accommodate multiple mold dies with different cavity configurations. The press is designed with a standardized mounting system that allows quick interchange of mold dies, enabling a single device to produce containers of various formats (single serve, family size, different shapes) without requiring separate dedicated devices for each format.
Solution Approach 2:
The patent introduces a dynamic mold die selection system where the type and configuration of mold dies can be changed during operation. The forming press works in conjunction with a storage system that holds multiple mold dies, allowing the system to adapt to different production requirements by selecting appropriate mold dies for different container formats needed at different times.
2Temperature
If containers are cooled in direct contact with the mold die after thermoforming, then cooling efficiency is improved, but material shrinkage causes deformation and reduces manufacturing precision
Solution Approach 1:
The patent extracts the container from direct contact with the mold die after the thermoforming process is complete. A ejection system removes the formed container from the mold cavity, allowing it to be transferred to a separate cooling station or conveyor. This separation prevents the container from being constrained by the mold die during cooling, eliminating shrinkage-induced deformation while still allowing efficient cooling through dedicated cooling mechanisms.
Solution Approach 2:
The patent introduces an intermediary ejection mechanism between the forming press and the cooling stage. This ejection system acts as a mediator that transfers the hot formed container from the mold die to a cooling conveyor or station without direct contact. The intermediary mechanism allows the container to cool freely without being constrained by the rigid mold die structure, preventing deformation while maintaining cooling efficiency.
3Productivity
If mold dies are fixed in the forming press for continuous production, then productivity is improved, but the ability to change container formats is reduced
Solution Approach 1:
The patent implements a dynamic mold die selection system where the type and configuration of mold dies can be changed during operation. The forming press works in conjunction with a storage system that holds multiple mold dies, allowing the system to adapt to different production requirements by selecting appropriate mold dies for different container formats needed at different times, thus maintaining both productivity and versatility.
Solution Approach 2:
The patent employs a storage system that prepositions multiple mold dies in readiness for quick changeover. Before a format change is needed, the appropriate mold die is prepared and positioned in the storage system, allowing for rapid interchange during production without significant downtime. This preliminary preparation enables format flexibility while maintaining continuous production flow.
4Manufacturing precision
If multiple separate devices are used for different container formats, then each device can be optimized for its specific format, but space requirements and installation complexity increase
Solution Approach 1:
The patent merges the functionality of multiple separate thermoforming devices into a single integrated forming press. By combining multiple mold die capabilities within one press unit, the system achieves the format-specific optimization benefits of multiple devices while occupying the space of only one device. The integrated system includes a unified heating system, forming mechanism, and ejection system that can accommodate various mold die configurations.
Solution Approach 2:
The patent implements a universal forming press that can accommodate multiple mold dies with different cavity configurations. The press is designed with a standardized mounting system that allows quick interchange of mold dies, enabling a single device to produce containers of various formats (single serve, family size, different shapes) without requiring separate dedicated devices for each format, thus reducing overall installation space.
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
Enables the production of containers in different formats and materials at a higher rate by allowing mold die exchange and preventing material deformation due to shrinkage, reducing production time and waste while optimizing space usage in industrial installations.
Implementation Method 1
a heater configured to heat the sheet of thermoformable material
Implementation Method 2
a forming press configured to thermoform at least one container by a pressing action on said heated sheet along an axis Z perpendicular to the plane P
Implementation Method 3
maintaining, when the container (21) has been thermoformed, an air gap between the container and the mold die during the cooling of the container (21)
Data Source
Figure 1~2
Figure 3
Figure 4~5D
AI summary
The present invention concerns a device for the continuous manufacture of containers (21) by thermoforming a sheet (23) of format f made from thermoformable material, the device comprising a carousel (32) configured to carry out the discontinuous transportation, in a closed circuit, of at least one mould die (33) for a forming press (31), said die (33) defining a container (21) format chosen depending on the format f of the sheet (23) and being interchangeable with another mould die (33), and each stop of the discontinuous transportation defining the position of a stop station for the mould die (33), at least one stop of the transportation defining the position of a stop station for the mould die (33) allowing said mould die (33) transported by the carousel (32) to be exchanged for another mould die (33).