Thermoplastic Forming Catching Device Air Flow Cooling
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Solution Overview
Problem
In thermoplastic material forming processes using hot molds, incomplete cooling can lead to permanent deformation and surface defects due to residual molten or softened states of the material when extracted from the mold, especially for fibrous or spongy structures.
Innovation Solution
A process involving a mold with a catching device and air flow system that contacts the semi-finished product to rapidly cool and solidify the material, using a distributed air flow to constrain and remove the product from the mold without manual intervention, ensuring stable mechanical constraints and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mould is opened immediately after forming to reduce process time, then productivity is improved, but the semi-finished product remains in a molten/softened state causing plastic deformation and surface defects
Solution Approach 1:
The catching device is positioned and ready before the mould opens. The air flow system is activated in anticipation of the mould opening, creating a cooling current that acts on the semi-finished product before it is extracted, preventing deformation during the transition from mould to catching device
Solution Approach 2:
The catching device acts as an intermediary between the hot mould and the external environment. It provides a temporary holding position where the semi-finished product can be transferred from the hot mould environment to a cooler environment, enabling immediate cooling without delay
2Manufacturing precision
If the semi-finished product is cooled rapidly to prevent deformation, then manufacturing precision is improved, but process time increases
Solution Approach 1:
A pneumatic system generates a directed air flow that acts as a cooling medium. The air flow current is generated by a blowing unit that directs cooled air onto the semi-finished product, enabling rapid heat removal without requiring the product to sit in a cool environment for extended periods
Solution Approach 2:
The system changes the thermal parameters of the semi-finished product by introducing a controlled air flow that modifies the cooling rate. The air flow creates a temperature gradient that accelerates heat transfer from the product to the environment, achieving rapid solidification
3Ease of operation
If manual intervention is used to remove the semi-finished product from the mould, then ease of operation is improved, but productivity decreases and deformation risk increases
Solution Approach 1:
The system is designed to automatically perform the removal operation. The catching device is positioned and activated automatically when the mould opens, and the air flow system automatically constrains and transports the semi-finished product without requiring manual intervention, making the process self-executing
Solution Approach 2:
The manual mechanical operation of removing and cooling the product is replaced by an automated system combining pneumatic air flow and mechanical catching device. The air flow provides both cooling and constraint functions, while the catching device provides mechanical support and positioning, eliminating the need for manual handling
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 process reduces process times by accelerating cooling and solidification, preventing deformation and surface damage, and allowing for high-quality surface conformation of the finished article.
Implementation Method 1
generating an air flow which passes through said coupling surface in a distributed way, said air flow being directed from said semi-finished product to said coupling surface
Implementation Method 2
heating said first and second half-mould for heating said semi-finished product
Data Source
AI summary
Process and station (99) for forming a thermoplastic material, the process comprising: —making a semi-finished product (10) in the thermoplastic material, the semi-finished product (10) being air permeable; —closing a mould (90) with the semifinished product (10) interposed between the conformation surfaces (3, 4) for compressing the semifinished product (10) between the conformation surfaces (3, 4); —heating the mould (90) for heating the semi-finished product (10), subsequently—opening the mould (90); —with the semi-finished product (10) coupled to a second half-mould (2) of the mould (90), contacting a free surface of the semi-finished product (10) with a coupling surface (80) of a catching device (71); —generating an air flow (200) which passes through the coupling surface (80) in a distributed way, the air flow being directed from the semi-finished product (10) to the coupling surface (80), for constraining the semi-finished product (10) to the catching device (71); —while keeping the airflow (200), removing the semi-finished product (10) from the mould (90) by movement of the catching device (71); —interrupting the air flow (200) for releasing the semi-finished product (10) from the catching device (71) and obtaining a finished article.