Tiered Container Molding Apparatus Vertical Stacking
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Solution Overview
Problem
Conventional blow molding devices can only produce one horizontal row of containers per molding cycle, limiting efficiency and requiring larger machinery and more resources.
Innovation Solution
A molding apparatus that forms an array or matrix of tiered or stacked containers by operating multiple mold sections within each parison, allowing for simultaneous production of multiple containers in a single molding cycle, reducing the footprint and resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional blow molding devices form only one horizontal row of containers per molding cycle, then the device complexity and footprint are reduced, but the productivity is significantly limited
Solution Approach 1:
The mold is divided into multiple independently operable sections (first mold section, second mold section, third mold section, fourth mold section) that can form containers at different levels. Each section can be operated separately to create tiered containers within a single parison, enabling vertical stacking of containers to increase production capacity without proportionally increasing device footprint.
Solution Approach 2:
The invention transitions from forming containers in a single horizontal dimension to forming containers in multiple vertical dimensions (tiers). By operating different mold sections at different vertical levels on the same parison, the system creates a three-dimensional array of containers, significantly increasing production capacity per molding cycle.
2Productivity
If multiple horizontal rows of containers are formed per molding cycle, then productivity increases, but the device footprint and size increase proportionally
Solution Approach 1:
Instead of expanding horizontally to form multiple rows of containers, the invention utilizes vertical space by forming tiered containers at different levels within the same parison. The mold sections are positioned at different vertical heights, allowing containers to be stacked upward rather than outward, thus increasing productivity while maintaining a compact footprint.
Solution Approach 2:
Multiple containers are nested vertically within a single parison structure. The first, second, third, and fourth mold sections form containers that are stacked one above another, similar to nested dolls, maximizing the use of vertical space within the confines of a single parison and minimizing the horizontal footprint.
3Productivity
If more mold sections are added to form tiered containers, then container production capacity increases, but the manufacturing complexity and cost increase
Solution Approach 1:
Each mold section (first, second, third, fourth sections) is designed with similar structural characteristics and operational mechanisms, allowing them to perform the same basic function of forming containers. This universality simplifies manufacturing and maintenance, as the same components and procedures can be replicated across multiple sections rather than designing entirely different mechanisms for each tier.
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
Significantly reduces the size and operational costs of molding machines, increases container production capacity, and minimizes scrap material, while allowing for flexible container arrangements.
Implementation Method 1
Gas is blown through the nozzle, into the parison to mold the body of the container
Implementation Method 2
each container can be blow molded and/or vacuum formed
Data Source
Figure 1
Figure 1A
Figure 1B
AI summary
A method and apparatus for molding a plurality of tiered containers from a single parison. Two or more parisons can be arranged next to each other. A molding apparatus of this invention can have one or more mold sections that can be operated in a controlled fashion to form a stacked or tiered arrangement of containers from a single parison or can be arranged to form an array of containers including two or more columns of containers each having two or more tiered containers, all during a single cycle of the molding apparatus. Each container formed by the method and apparatus of this invention can be blow molded and/or vacuum formed and/or filled and/or sealed. Each seal can be a hermetic seal or any other suitable seal formed through a molding step.