Valve Element Dynamics in Molded Article Holder Air Flow Control
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Solution Overview
Problem
Existing molded article holders face challenges in efficiently transferring and ejecting molded articles due to air pressure losses and mechanical complexity, leading to inconsistent ejection times and reduced productivity in injection molding systems.
Innovation Solution
A molded article holder with a pressure channel and valve system that includes a device portal and plenum portal, where the valve element moves between open and blocking positions to minimize pressure drop and air flow resistance, ensuring reliable transfer and ejection of molded articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional pressure channel without valve optimization is used, then the structure is simple, but air pressure losses are high and air flow resistance is high
Solution Approach 1:
The valve element is designed to move dynamically between different positions (open and closed) based on operational requirements. This dynamic capability allows the system to optimize air flow during transfer operations while maintaining pressure during ejection, resolving the contradiction between energy loss and structural simplicity
Solution Approach 2:
The pressure channel is segmented into multiple sections with different valve elements positioned at different locations. This segmentation allows independent control of air flow at different stages of the operation, enabling optimized air flow paths that reduce pressure losses without requiring complete system redesign
2Reliability
If mechanical ejection systems are used, then ejection reliability is high, but device weight increases and mechanical complexity increases
Solution Approach 1:
The patent replaces traditional mechanical ejection systems with a pneumatic system using compressed air delivered through optimized pressure channels and valve elements. This substitution eliminates heavy mechanical components while maintaining ejection reliability through controlled air pressure application
Solution Approach 2:
The system uses pneumatic principles to achieve ejection through compressed air delivery. The optimized pressure channels and valve elements work together to deliver precise air pressure to eject molded articles, replacing mechanical force with pneumatic force to reduce weight and complexity
3Productivity
If fast cycling speeds are achieved, then productivity increases, but larger driving motors are required and energy consumption increases
Solution Approach 1:
The valve elements operate in periodic cycles, opening during transfer operations to allow air flow and closing during ejection to maintain pressure. This periodic action synchronizes with the molding cycle to enable fast cycling speeds while optimizing energy usage by only activating systems when needed
Solution Approach 2:
The system changes operational parameters dynamically - air pressure, valve position, and flow rate are adjusted based on the operational phase. During transfer, valves open to allow air flow; during ejection, valves close to maintain pressure. These parameter changes enable fast cycling without requiring continuously high energy input
4Reliability
If pressure channel design does not minimize pressure drop, then air flow is sufficient, but transfer reliability is inconsistent
Solution Approach 1:
The valve elements are positioned and configured in advance to optimize air flow paths before transfer operations begin. The pressure channel geometry is designed beforehand to minimize pressure drop, ensuring consistent air flow and reliable transfer without requiring real-time adjustments
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
The solution achieves low pressure drop across the valve, improving suction air flow and compressed air conservation, resulting in more reliable transfer and ejection of molded articles, enhancing productivity and reducing mechanical complexity.
Implementation Method 1
With a lower air pressure at the plenum portal than the device portal, the valve element movable to an open position behind the device and plenum portals at least in part. With a higher air pressure at the plenum portal than the device portal, the valve element movable to a blocking position between the device and plenum portals
Implementation Method 2
connecting the cooling/extraction pins 14 to a negative pressure source, thereby creating a vacuum within the region of the molded articles 2
Implementation Method 3
the cooling of the molded articles 2 may be assisted by the use of cooling/extraction pins 14 expelling a cooling fluid onto exposed portions of the molded articles 2
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Disclosed, amongst other things, is: (i) a valve (220, 320, 420, 520, 620) for controlling air flow in an air pressure channel (354, 454) of a molded article holder (50, 150, 250, 350, 450); (ii) a molded article holder (350, 450) co-operable with the valve (220, 320, 420, 520, 620); and (iii) a post-mold holding device (315, 415) including the molded article holder (350, 450) and valve (220, 320, 420, 520, 620).