Systems and process improvements for high speed forming of containers using porous or other small mold surface features

Patent metadata

Field	Value
Publication number	US-10875073-B2
Application number	US-201815943999-A
Country	US
Kind code	B2
Filing date	Apr 3, 2018
Priority date	May 4, 2014
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

Systems and methods of forming articles using electromagnetic radiation are disclosed. In some aspects, the system includes a plurality of forming modules movably mounted relative to an infeed mechanism. The infeed mechanism is configured to supply pre-form articles to the plurality of forming modules, and each of the plurality of forming modules includes a multi-segment mold disposed about an electromagnetic coil. The electromagnetic coil is configured to impart an electromagnetic force on the pre-form articles when supplied with electrical energy that urges the pre-form articles into contact with the multi-segment mold to produce the formed containers. The multi-segment mold having a plurality of segments, each segment including a mold insert having an inner surface. The plurality of inner surfaces defining a desired shape of the formed containers. Each mold insert being comprised of a material that comprises at least one of small pores, grooves, pockets and crevices. The material comprising the at least one of small pores, grooves, pockets and crevices being configured to allow air to pass through the multi-segment mold or to allow the air to be less compressed.

First claim

What is claimed is:

1. A rotary-turret system for forming a plurality of formed containers from a respective plurality of pre-form articles using electromagnetic energy, the system comprising:
a rotary turret having a plurality of forming modules, the forming modules being disposed about the periphery of the rotary turret, each forming module including a multi-segment mold disposed about an electromagnetic coil, the multi-segment mold having a plurality of segments, each segment including a mold insert having an inner surface, the plurality of inner surfaces defining a desired shape of the formed containers, the electromagnetic coil being configured to impart an electromagnetic force on the pre-form articles when supplied with electrical energy, the electromagnetic force configured to urge the pre-form articles into contact with the inner surfaces of the multi-segment mold to produce the formed containers, each mold insert being comprised of a material that comprises at least one of small pores, grooves, pockets and crevices;
a charging circuit configured to supply the electrical energy to the rotary turret; and
a discharge-control mechanism operatively coupled to the rotary turret and the charging circuit, the discharge-control mechanism configured to selectively actuate discharge of the electrical energy from the charging circuit to a predetermined one of the plurality of forming modules,
wherein the rotary turret continually rotates during forming of the plurality of formed containers, and wherein the material that comprises at least one of small pores, grooves, pockets and crevices is configured to allow air to pass through the multi-segment mold or to allow the air to be less compressed.

2. The rotary-turret system of claim 1 , wherein the material that comprises at least one of small pores, grooves, pockets and crevices includes at least one of a sintered material, a ceramic material, an aluminum oxide, a hard metal or composite, and any hard durable material that would allow air to pass through the multi-segment mold, or combinations thereof.

3. The rotary-turret system of claim 1 , wherein the material that comprises at least one of small pores, grooves, pockets and crevices is mechanically perforated by a laser, a water jet, machining, or other similar methods.

4. The rotary-turret system of claim 1 , further comprising a compressed-air system and a vacuum system, the compressed-air system configured to pressurize an internal volume disposed between the pre-form article and the electromagnetic coil to a predetermined pressure, the vacuum system configured to evacuate a volume between the pre-form article and the inner surface of the multi-segment mold.

5. The rotary-turret system of claim 4 , wherein the material comprising at least one of small pores, grooves, pockets and crevices is configured to reduce or negate the need to evacuate at a high vacuum level produced from the vacuum system.

6. The rotary-turret system of claim 1 , wherein the small pores, grooves, pockets or crevices contribute to a resulting surface texture of the formed containers without reducing the quality of the formed containers.

7. The rotary-turret system of claim 6 , wherein the resulting surface texture due to the small pores, grooves, pockets or crevices enhances one or more cosmetic features of the formed containers.

8. The rotary-turret system of claim 7 , wherein the small pores, grooves, pockets, or crevices are characterized by varying sizes and geometries to balance the functional aspects with the cosmetic features of the formed containers.

9. A system for forming a plurality of formed containers from a plurality of pre-form articles using electromagnetic energy, the system comprising:
a rotary turret including a plurality of forming modules, the rotary turret being movably mounted relative to an infeed mechanism, the infeed mechanism configured to supply pre-form articles to the plurality of forming modules, each of the plurality of forming modules including a multi-segment mold disposed about an electromagnetic coil, the multi-segment mold having a plurality of segments, each of the plurality of segments including a mold insert having an inner surface, the plurality of inner surfaces defining a desired shape of the formed containers, the electromagnetic coil being configured to impart an electromagnetic force on the pre-form articles when supplied with electrical energy, the electromagnetic force being configured to urge the pre-form articles into contact with the inner surfaces of the multi-segment mold to produce the formed containers, each mold insert being comprised of a material that comprises at least one of small pores, grooves, pockets and crevices;
a charging circuit being configured to supply the electrical energy to the plurality of forming modules;
a discharge-control mechanism operatively coupled to the plurality of forming modules and the charging circuit, the discharge-control mechanism being configured to selectively actuate discharge of the electrical energy from the charging circuit to a predetermined forming module, and
wherein the material that comprises at least one of small pores, grooves, pockets and crevices is configured to allow air to pass through the multi-segment mold or to allow the air to be less compressed.

10. The system of claim 9 , further comprising a compressed-air system and a vacuum system, the compressed-air system being configured to pressurize an internal volume disposed between the pre-form article and the electromagnetic coil to a predetermined pressure, the vacuum system being configured to evacuate a volume between the pre-form article and the inner surface of the multi-segment mold.

11. The system of claim 10 , wherein the material comprising at least one of small pores, grooves, pockets and crevices is configured to reduce or negate the need to evacuate at a high vacuum level produced from the vacuum system.

12. The system of claim 9 , wherein the small pores, grooves, pockets or crevices contribute to a resulting surface texture of the formed containers without reducing the quality of the formed containers.

13. The system of claim 12 , wherein the resulting surface texture due to the small pores, grooves, pockets or crevices enhances one or more cosmetic features of the formed containers.

14. The system of claim 13 , wherein the small pores, grooves, pockets, or crevices are characterized by varying sizes and geometries to balance the functional aspects with the cosmetic features of the formed containers.

Assignees

• Belvac Production Machinery Inc

Inventors

• Lee Richard H

Classifications

• B21D51/2615

  Edge treatment of cans or tins · CPC title

• B30B11/08

  co-operating with moulds carried by a turntable · CPC title

• B21D26/14 Primary

  applying magnetic forces · CPC title

• B21D51/2607

  Locally embossing the walls of formed can bodies (B44B5/00, B44C1/24, B44C3/085 take precedence; bulging B21D51/2646) · CPC title

• B21D51/2692

  Manipulating, e.g. feeding and positioning devices; Control systems · CPC title