Thermoforming Mold with Axially Movable Insert for Undercut Containers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thermoforming tools face challenges in reliably producing containers with continuous circumferential undercuts, which are difficult to demold without damaging, due to complex and space-intensive technologies that cannot produce such features effectively.
Innovation Solution
A molding tool with a stationary first mold insert part and an axially movable second mold insert part, allowing for seamless cavity formation during molding and controlled axial displacement during demolding, facilitating the production of containers with continuous undercuts by synchronously or asynchronously moving the mold bottom and second mold insert part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermoforming tools are used to produce containers with continuous circumferential undercuts, then the containers can be molded with desired stacking and stability features, but the demolding process becomes difficult and may destroy the containers
Solution Approach 1:
The mold insert is divided into two separate parts: a first mold insert part that remains stationary and a second mold insert part that can move axially. This segmentation allows the mold to maintain the undercut shape during molding while enabling demolding by moving the second part, thus resolving the contradiction between producing accurate container shapes with undercuts and successfully demolding the containers without damage.
2Manufacturing precision
If complex pusher and eccentric devices are used to produce containers with undercuts, then local undercuts can be achieved, but the device complexity and installation space increase significantly
Solution Approach 1:
Instead of using complex pusher and eccentric devices, the invention segments the mold insert into two parts where the second part can move axially. This simpler segmented approach achieves the same undercut formation capability without requiring complex mechanical devices, thereby reducing device complexity and installation space while maintaining manufacturing precision for undercut features.
Solution Approach 2:
The second mold insert part is made movable in the axial direction, introducing dynamic capability to the mold structure. This dynamic element allows the mold to adapt its configuration during the molding and demolding cycles, enabling undercut formation and subsequent demolding with a simple axial movement mechanism rather than complex fixed mechanisms.
3Ease of operation
If the mold bottom is lifted to demold containers with undercuts, then containers can be released from the mold, but the lifting movement may cause containers to release completely and be damaged
Solution Approach 1:
By segmenting the mold insert into two parts, the demolding process can be controlled more precisely. The second movable part can be axially displaced to facilitate demolding without requiring complete lifting of the mold bottom, allowing for controlled release that maintains container integrity while achieving ease of operation in the demolding process.
Solution Approach 2:
The movable second mold insert part allows for localized control of the demolding process. Instead of lifting the entire mold bottom which affects the whole container, only the region corresponding to the second mold insert part moves, providing localized demolding action that releases containers gently without causing complete release and damage.
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 reliable and gentle demolding of containers with high side walls and undercuts, reducing the risk of damage and allowing for efficient production of containers with continuous circumferential undercuts, improving throughput and tool efficiency.
Implementation Method 1
During a thermoforming process, first a thermoplastic film is heated and arranged between the upper mold part and the lower mold part
Implementation Method 2
compressed air (also called molding air) is introduced into the cavity and/or a negative pressure (vacuum) is produced in the cavity. This presses the premolded film further against the mold side wall
Implementation Method 3
compressed air (also called molding air) is introduced into the cavity and/or a negative pressure (vacuum) is produced in the cavity
Implementation Method 4
The plastic film thus completely molded is then cooled, so that a container with rigid walls is created
Data Source
AI summary
A molding tool (1000), in particular a thermoforming tool, for producing a container (10) is provided. The molding tool comprises a mold bottom (200) and a mold insert (100) receiving the mold bottom (200), wherein the mold insert (100) is constructed of at least two mold insert parts (110, 120) that together with the mold bottom (200) define a cavity (300) provided for reshaping a two-dimensional web of material into a container, wherein a first mold insert part (110) is mounted stationary in the molding tool (1000) and a second mold insert part is axially movable in the molding tool (1000).