Valve Block Resin Flow Control for Varying Thickness Parison
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Solution Overview
Problem
Existing methods for producing containers with varying resin layer thicknesses have low production rates due to synchronization requirements and flow characteristics, limiting output to less than 40 containers per minute.
Innovation Solution
An apparatus and method that utilize a valve block with a duct and a second extruder to control the flow of molten polymer resin, allowing for the formation of parisons with varying thickness layers by adjusting the pressure and flow of the resin through a valve and accumulator cylinder, synchronized with a flow head to ensure consistent layer placement across containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a valve block with duct and second extruder is used to control resin flow, then production rate increases to 180 containers per minute, but device complexity increases
Solution Approach 1:
The resin supply system is segmented into multiple independent extruders (first extruder for base resin, second extruder for varying thickness resin) with separate control pathways. The valve block segments the flow control into distinct ducts and valves for each resin layer, allowing independent optimization of each stream's flow rate and timing, thereby enabling high-speed production without compromising control precision.
Solution Approach 2:
The valve block with its internal duct system serves as an intermediary component that mediates between the second extruder and the flow head. This intermediary structure provides precise flow control through integrated valves and channels, enabling the complex task of varying resin layer thickness to be managed through a dedicated intermediate component rather than direct extruder-to-head control.
2Manufacturing precision
If resin flow is controlled through valve and accumulator cylinder, then layer thickness precision improves, but device complexity increases
Solution Approach 1:
The accumulator cylinder performs preliminary action by storing pre-measured quantities of molten resin before they enter the flow head. This pre-accumulation ensures that the exact required amount of resin is available at the precise moment needed for forming each container layer, eliminating variability in layer thickness and enabling consistent precision across all containers produced at high speed.
Solution Approach 2:
The control system incorporates feedback mechanisms that monitor the flow of molten resin through the valve block and accumulator cylinder. By continuously measuring actual resin flow rates and layer formation progress, the system automatically adjusts valve timing and accumulator discharge rates to maintain precise layer thickness control, compensating for any deviations in real-time.
3Stability of the object's composition
If multiple extruders and valve block are integrated, then consistency of layer placement improves, but ease of manufacture deteriorates
Solution Approach 1:
Multiple functional components (second extruder, valve block with ducts, accumulator cylinder, and control system) are merged into a single integrated resin delivery system. This consolidation ensures that all components work in synchronized harmony, with pre-established flow pathways and coordinated control mechanisms that guarantee consistent layer placement. The integrated design eliminates misalignment issues that would arise from separate, loosely-coupled components.
4Productivity
If production rate is increased to 180 containers per minute, then productivity improves, but manufacturing precision may deteriorate
Solution Approach 1:
The system maintains continuous operation of all extruders and control mechanisms throughout the production cycle. The first and second extruders continuously feed molten resin through the valve block and accumulator cylinder without interruption, even at production rates of 180 containers per minute. This continuous flow ensures that resin is always available at the exact moment needed for layer formation, eliminating delays or variations that would compromise precision at high speeds.
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 approach enables production rates to increase significantly, up to 180 containers per minute, by precisely controlling the thickness and placement of resin layers, enhancing the efficiency and consistency of multi-layer container production.
Implementation Method 1
controls the flow of the molten polymer resin directly from the second extruder to the flow head
Implementation Method 2
A valve is positioned within the duct and controls the flow of the molten polymer resin
Implementation Method 3
An accumulator cylinder is in fluid communication with the duct at a position between the valve and the outlet. A piston is reciprocably movable within the cylinder for controlling pressure of the molten polymer resin within the duct
Implementation Method 4
A second extruder is in fluid communication with the inlet, the second extruder supplying molten polymer resin to the duct
Implementation Method 5
The parison is formed in the flow head and flows away therefrom
Data Source
AI summary
An apparatus for producing a parison having a plurality of resin layers and at least one resin layer of varying thickness is disclosed. The parison is used to form containers in a blow mold machine. An extruder is in communication with a flow head to form the parison. The apparatus includes a valve block having a duct providing communication between a second extruder and the flow head. Flow of resin from the second extruder directly to the flow head is controlled by a valve in the valve block. An accumulator cylinder and piston are also in communication with the duct and control the resin pressure within the duct. Opening and closing the valve and stroking the piston sends resin from the second extruder to the flow head and forms a resin layer having a varying thickness on the parison. A method of forming a varying layer is also disclosed.