Thermoforming Apparatus with Segmented Rotor for Productivity
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Solution Overview
Problem
Existing thermoforming apparatuses for plastic containers have limited productivity, require complex construction, and lack versatility for producing containers of different sizes and shapes, necessitating multiple machines and increased costs.
Innovation Solution
The apparatus features a system with multiple thermoforming devices, a rotor with independently heated closing elements, and interchangeable shaped molds and cutting systems, allowing simultaneous production of multiple containers and easy size changes, with a simplified extraction mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotary rotor with multiple closing elements is used to increase productivity, then production capacity improves, but device complexity increases due to independent heating systems for each closing element
Solution Approach 1:
The rotor is divided into multiple independent closing elements (first closing element, second closing element, etc.) that can operate independently. Each closing element has its own heating system, allowing simultaneous heating of multiple flat sheets at different positions, thereby increasing production capacity while maintaining manageable complexity through modular design
Solution Approach 2:
The rotor enables continuous operation by having multiple closing elements positioned at different angular locations (e.g., 0°, 90°, 180°, 270°). While one closing element is heating a flat sheet, others can be positioned at the forming station or receiving station, ensuring continuous production without idle time and maximizing productivity
2Adaptability or versatility
If multiple shaped molds are used to produce different container sizes, then versatility improves, but device complexity and cleaning difficulty increase
Solution Approach 1:
The apparatus is designed with universal closing elements that can work with multiple shaped molds of different sizes and configurations. The closing elements are positioned and dimensioned to accommodate various container types, allowing a single closing element to serve multiple functions across different production scenarios, thereby improving versatility without proportionally increasing complexity
Solution Approach 2:
The rotor and closing elements are designed with dynamic positioning capabilities, allowing adjustment of the closing elements' positions and orientations to match different shaped molds. This dynamic adaptability enables the system to handle various container sizes and shapes using the same basic hardware, reducing the need for multiple specialized components
3Adaptability or versatility
If a single apparatus is used for multiple container sizes, then versatility improves, but productivity decreases due to change-over time and complexity
Solution Approach 1:
The rotor positions multiple closing elements in advance at different angular locations, so that while one closing element is engaged in heating or forming, others are already prepared or positioned for the next operation. This preliminary positioning minimizes change-over time and maintains continuous production flow, preserving productivity while enabling versatility
Solution Approach 2:
The system uses multiple identical or similar closing elements mounted on the rotor, each capable of performing the same heating and forming functions. This redundancy allows the apparatus to switch between different container sizes by simply repositioning or reconfiguring the closing elements, rather than requiring complete system changes, thereby maintaining high productivity across different production runs
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 solution enhances productivity, reduces complexity, and increases versatility, enabling efficient production of various container sizes and shapes with minimal changes to the apparatus, while maintaining cost-effectiveness.
Implementation Method 1
the closing elements, which are internally equipped with suitable heating means, heat the flat sheet to the temperature necessary for thermoforming
Implementation Method 2
the shaped mould and the closing element clamp a flat sheet between them
Implementation Method 3
A flat sheet of thermoformable plastic material is positioned on the closing element (equipped with a suction retaining system)
Data Source
AI summary
An apparatus for thermoforming plastic containers comprising a pickup station (24), a feeder (25) for feeding flat sheets (8) of thermoformable plastic material to the pickup station (24), at least one thermoforming device (3), and a transferring device (26) for transferring the flat sheets (8) from the pickup station (24) to the thermoforming device (3), the feeder (25) comprising at least one support (50) for a reel (51) of a web (52) of thermoformable plastic material, unwinding means (53) for unwinding the reel (51) of web (52) which are designed, in use, to feed the web (52) along a sliding path extending from the at least one support (50) to the pickup station (24), and a cutting device (54) for cutting the web (52), positioned along the sliding path, for dividing the web (52) into a plurality of pieces each of which corresponds to a flat sheet (8) to be fed to the pickup station (24).