Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of blow molding technology. In particular, the present disclosure relates to an improved and efficient blow molding machine and a method thereof.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Blow molding machines have long been an integral part of the manufacturing industry, enabling the production of a diverse range of hollow plastic products. Referring to FIGs. 1A and 1B, the conventional design of blow molding machines 100 typically includes a hopper 102 connected to a barrel 104 containing a static screw 106 and a heating element. The heating element serves to melt the raw material (RM) fed from the hopper 102, and the molten material is then extruded towards a die-head 108 through the rotation of the screw 106.
[0004] While effective, the existing blow molding machines 100 face challenges related to energy consumption, resource utilization, and maintenance requirements. The conventional initiation of the blow molding process involves starting the machine 100 before introducing raw material, allowing for the heating element to achieve optimum temperature conditions for the specific raw material. This approach, while common, has limitations in terms of efficiency and energy consumption.
[0005] The subsequent steps involve feeding the raw material into the machine hopper 102 and tuning the machine 100 for heating based on the raw material's specific requirements. Machine parameters are then set according to the intended article or mold. A critical aspect of the blow molding process involves configuring a gearbox 110 to accommodate the appropriate raw material, ensuring the efficient rotation of the screw 106 within the barrel 104 to achieve the desired melt. Upon reaching the desired melt result, the molten material is extruded into the die-head 108 through the continued rotation of the screw 106.
[0006] The die-head 108 plays a pivotal role in shaping the raw (plastic) material into the desired form, adapting to two standard processes: continuous extrusion and accumulator extrusion. In continuous extrusion machines as shown in FIG. 1A, the die-head 108 continuously produces a parison with a desired diameter, incorporating a die-mold for shaping. Alternatively, in accumulator machines as shown in FIG. 1B, the die-head 108 stores molten material from the screw within an accumulator tank 112. The shot is extruded only when the mold is ready to receive the parison, a process particularly beneficial for heavy-weight articles, ensuring accuracy and shorter cycle times.
[0007] The cyclical nature of the blow molding process necessitates the utilization of various components, including Gearbox, Hydraulic Motor, Chain Pulley, AC Drive, Hydraulic Valves, and optional Servo Motor (for hydraulics), as well as Manifolds. These components, while essential, are prone to wear and tear, resource-intensive, consume significant amounts of electricity, and require periodic maintenance.
[0008] In addition, in typical machines, the article's weight is contingent upon the die-head and die-mold. The die-mold plays a pivotal role in adjusting the available gap for molten raw material to flow through the die-head, ultimately forming the parison. Following the standard process, the raw material is continuously extruded to shape the parison through the controlled rotation of the screw, which is regulated by the gearbox. Any reduction in the gap through the die-mold, initiated by the processor, results in the failure of molten raw material extrusion. This leads to the material swirling up at the end of the die-head, causing a critical failure in obtaining the required parison. Consequently, it becomes unfeasible to produce a 5L article weighing 100 grams in a standard machine.
[0009] Further, the article thickness is purely dependent on the die-head and the die-mold. Since the parison is extruded by the rotation of the screw via a gearbox, the processor can only increase the speed of extrusion by alternating the screw rpm. Since the blow molding process, parison is acting against the force of gravity, it is observed that articles have uneven wall thickness because of additional stretch caused by gravitational pull.
[0010] Furthermore, the color used is either through masterbatch or pigment or colored RM to produce articles with a desired color. When processors need to change color, the processor has to do purging of the screw by using at least 1 bag of uncolored virgin RM to clean the internals of the screw, barrel, and die-head to remove any traces of the previous color. Post this process, the processor starts the molding process with a new color. If lines, streaks or patches of previous color are observed, the processor has to dismantle the die-head or the screw and polish the components for removal of any traces of color or carbon deposit to ensure the transition to new color without any spots.
[0011] Moreover, in typical machines, there are a lot of components required for the operation of the machine. With the hydraulic motor and gearbox running continuously at high speeds, the circulated oil is exposed to frictional and mechanical heat. This makes the circulated oil gain heat with each operation and results in oil temperature increase in the tank. There is a cooling chamber placed in the machine to cool the oil. Since the operational heat cannot be predicted, the oil is exposed to changing temperatures and degrades the life of valves, seals, and components increasing maintenance costs.
[0012] There is, therefore, a requirement in the art for a means to overcome the above drawbacks, shortcomings, and limitations associated with the existing blow molding machines, by providing an improved and streamlined approach solution to enhance efficiency, reduce resource consumption, and minimize maintenance requirements, thereby contributing to a more sustainable and cost-effective blow molding process.

OBJECTS OF THE PRESENT DISCLOSURE
[0013] Some of the objects of the present disclosure, which at least one embodiment herein satisfy are as listed hereinbelow.
[0014] It is an object of the present disclosure to overcome the above-mentioned drawbacks, shortcomings, and limitations associated with existing blow molding machines.
[0015] It is an object of the present disclosure to provide a simple and efficient blow molding solution that involves a reduced number of components compared to existing solutions in order to achieve the blow molding process,
[0016] It is an object of the present disclosure to provide a simple and efficient blow molding solution that is less prone to failure and is easy to maintain and service.
[0017] It is an object of the present disclosure to provide a simple and efficient blow molding solution that creates articles having uniform wall thickness without the involvement of additional machines.
[0018] It is an object of the present disclosure to provide a simple and efficient blow molding solution that is exposed to less frictional heat and wear and tear, thereby remaining at ambient temperature and further reducing the maintenance cost.
[0019] It is an object of the present disclosure to an improved and streamlined blow molding machine and process to enhance efficiency, reduce resource consumption, and minimize maintenance requirements, thereby contributing to a more sustainable and cost-effective blow molding process.

SUMMARY
[0020] The present disclosure relates to the field of blow molding. In particular, the present disclosure relates to an improved, easy-to-use, and efficient blow molding machine and a method thereof.
[0021] According to an aspect, an extruder for a blow molding machine is disclosed. The extruder comprises a hollow barrel having an open first end fluidically connected to a hopper, wherein the hopper is configured to receive and supply raw material at the first end within the barrel. The machine further comprises a heating element configured at the first end of the barrel to heat and melt the material supplied via the hopper, a die-head fluidically connected to a second open end of the barrel, and a screw extending longitudinally through the barrel such that a first end of the screw remains at or at least partially outside of the first end of the barrel. The screw is rotatably and linearly configured within the barrel, wherein rotation of the screw within the barrel enables movement of the molten material from the second end towards the second end of the barrel or the die-head and wherein linear movement of the screw towards the second end of the barrel enables extrusion of the molten material via the die-head
[0022] In an aspect, the extruder comprises a servo-hydro motor operatively coupled to the first end of the screw. The servo-hydro motor is configured to rotate the screw within the barrel about a longitudinal axis of the barrel, and linearly move the screw between a first position and a second position. At the first position, a second end, opposite to the first end, of the screw remains away from the second end of the barrel. Further, at the second position, the second end remains at the second end of the barrel.
[0023] In an aspect, the extruder comprises a controller operatively coupled to the heating element and the servo-hydro motor. The controller is configured to: adjust temperature of the heating element at a predefined temperature to melt the material received at the first end of the barrel; rotate the screw at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel based on a volume of the molten material and a pressure at which the molten material is to be to be transferred from the first end towards the second end of the barrel; and/or linearly move the screw at a predefined linear speed and a predefined frequency within the barrel based on the volume of the molten material and a flow-rate at which the molten material is to be extruded from the die-head into the die-mold.
[0024] According to an aspect, a blow molding machine is disclosed. The machine comprises an extruder comprising a hollow barrel having an open first end fluidically connected to a hopper, wherein the hopper is configured to receive and supply material at the first end within the barrel, a heating element configured at the first end of the barrel to heat and melt the material supplied via the hopper, a die-head fluidically connected to a second open end of the barrel, and a screw extending longitudinally through the barrel such that a first end of the screw remains at the first end of the barrel. The screw is rotatably and linearly configured within the barrel, wherein rotation of the screw enables movement of the molten material from the second end towards the second end of the barrel or the die-head and wherein linear movement of the screw towards the second end of the barrel enables extrusion of the molten material via the die-head. The machine further comprises a die-mold having an opening and an inner cavity having a predefined profile based on a shape of an article to be fabricated, wherein the machine is configured to securely position the die-mold below the die-head of the extruder such that the linear movement of the screw towards the second end of the barrel enables extrusion of the molten material via the die-head into the die-mold
[0025] In an aspect, the extruder comprises a servo-hydro motor operatively coupled to the first end of the screw. The servo-hydro motor is configured to rotate the screw within the barrel about a longitudinal axis of the barrel, and linearly move the screw between a first position and a second position. At the first position, a second end, opposite to the first end, of the screw remains away from the second end of the barrel. Further, at the second position, the second end remains at the second end of the barrel.
[0026] In an aspect, the machine comprises a controller that is operatively coupled to the heating element and the servo-hydro motor. The controller is configured to: adjust the temperature of the heating element at a predefined temperature to melt the material received at the first end of the barrel; rotate the screw at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel based on a volume of the molten material and a pressure at which the molten material is to be to be transferred from the first end towards the second end of the barrel; and/or linearly move the screw at a predefined linear speed and a predefined frequency within the barrel based on the volume of the molten material and a flow-rate at which the molten material is to be extruded from the die-head into the die-mold.
[0027] In an aspect, the machine comprises a blow pin configured to be inserted within the cavity of the die-mold upon filling of the molten material within the die-mold. The controller enables the blow pin to blow a fluid at a predefined pressure within the cavity filled with molten material to form the article within the die-mold. Further, the die-mold is configured to be opened upon curing or cooling of the article to allow separation of the formed article from the die-mold.
[0028] According to an aspect, a blow molding method comprises: supplying a material into a hollow barrel, wherein a first end of the barrel is fluidically connected to a die-head; heating the material at a predefined temperature within the barrel to melt the material; rotating the screw at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel based on a volume of the molten material and a pressure at which the molten material is to be to be transferred towards the die-head, and linearly moving the screw at a predefined linear speed and a predefined frequency within the barrel based on the volume of the molten material and a flow-rate at which the molten material is to be extruded from the die-head into a die-mold.
[0029] In an aspect, the method comprises the steps of inserting a blow pin within a cavity of the die-mold upon filling of the molten material within the die-mold; blowing, via the blow pin, a fluid at a predefined pressure within the cavity filled with the molten material to form the article within the die-mold.
[0030] In an aspect, the method comprises the steps of opening the die-mold upon curing or cooling of the article to allow separation of the formed article from the die-mold.
[0031] Various objects, features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent features.
[0032] Within the scope of this application, it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible

BRIEF DESCRIPTION OF DRAWINGS
[0033] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and, together with the description,
[0034] FIGs. 1A and 1B illustrates exemplary view of existing blow molding machines, in accordance with an embodiment of the present disclosure.
[0035] FIGs. 2A to 2D illustrates exemplary views of the extruder used in the proposed blow molding machine, in accordance with an embodiment of the present disclosure.
[0036] FIGs. 3A to 3C illustrates exemplary views of the proposed blow molding machine, in accordance with an embodiment of the present disclosure
[0037] FIG. 4 illustrates an exemplary flow diagram of the proposed blow molding process, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0039] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[0040] Embodiments of the present disclosure elaborate upon an improved, easy-to-use, and efficient blow molding machine and a method thereof.
[0041] Referring to FIGs. 2A to 3C, the proposed blow molding machine 300 “machine 300” can include an extruder 200 configured over a frame, where the frame can include a foundation frame 302-1 and a body frame 302-2 configured on top of the foundation frame 302-1. The machine 300 can further include a clamping assembly 304 securely positioned on the body frame 302-2, which can clamp or secure a die-mold (not shown) thereon such that the die-mold remains below an extrusion outlet of the extruder 200. In an embodiment, the die-mold can have an opening and an inner cavity having a predefined profile based on the shape of an article to be fabricated using the material.
[0042] In an embodiment, as shown in FIGs. 2A to 2D, the extruder 200 of the machine 300 can include a hollow barrel 202 having an open first end and a second open end. The extruder 200 can further include a hopper 204 fluidically connected to the first end of the barrel 202 and configured to receive and supply raw material(s) into the first end within the barrel 202. In addition, in an embodiment, a heating element (not shown) can be configured at the first end of the barrel 202 to heat and melt the material supplied via the hopper 204 to create molten material within the second end of the barrel 202. However, in some embodiments, the heating element can also be configured at the bottom end of the hopper 204. In an exemplary embodiment, the heating element can be selected from any or a combination of resistance wire elements, ceramic infrared heaters, mica band heaters, halogen heating elements, quartz infrared heaters, coil heaters, open coil elements, but is not limited to the like. Further, a die-head 206, which acts as the extrusion outlet, can be fluidically connected to the second open end of the barrel 202.
[0043] In an exemplary embodiment, the raw material can be selected from a group comprising Polyethylene (PE – HDPE, LDPE, HMHDPE, LMHDPE, HMLDPE, LMLDPE, MDPE, LDPE), Polypropylene (PP, Standard, Random), Thermoplastic Elastomer (TPE), Thermoplastic Rubber (TPR), Thermoplastic Olefin (TPO), Ethylene Vinyl Acetate (EVA), Polyethylene Vinyl Acetate (PEVA), Glass Filled, Talc Filled, Polyvinyl Chloride (PVC - Rigid, Flexible), Acrylonitrile Butadiene Styrene (ABS), Nylon, Polycarbonate (PC), TRITAN, Polyethylene-Terephthalate (PET), Recycled Pet (RPET), Polyethylene Terephthalate Glycol-modified (PETG), Co-polyester, SANTOPRENE or other material obtained through post consumer resin (PCR).
[0044] In an exemplary embodiment, but not limited to the like, die-head 206 can have a diameter of 0/5 to 5000mm, with an article size range of 0.1 ml to 20000 litres and a shot (parison) capacity of 0.1 gm to 1000kg.
[0045] In an embodiment, a screw 208 having a helical profile can be configured coaxially within the barrel 202 such that the screw 208 extends longitudinally therethrough, with a first end of the screw 208 extending at least partially outside of the first open end of the barrel 202. In an exemplary embodiment, the screw 208 can have a diameter of 5mm to 500mm with a screw 208 L/D ratio range of 05;01 to 300:01. In addition, the screw 208 can be rotatably as well as linearly configured within the barrel 202. In an implementation, rotation of the screw 208 within the barrel 202 can enable movement of the molten material from the second end towards the second end of the barrel 202 or into the die-head 206. In addition, the linear movement of the screw 208 towards the second end of the barrel 202 can enable extrusion of the molten material (parison) into the die-mold via the die-head 206.
[0046] In an exemplary embodiment, the barrel 202 can be a cylindrical housing of a predefined length and predefined diameter. However, the barrel 202 can also have other shapes, without any limitation. Further, an outlet (bottom end) of the hopper 204 can be fluidically connected to a top circular surface at the first end of the barrel 202 and the screw 208 can be movably inserted within the barrel 202 from the first open side (base side of the cylindrical housing) of the barrel 202. However, the outlet of the hopper 204 can also be connected at any other surface at the first end of the barrel 202, without any limitation, and all such embodiments are well within the scope of the present disclosure.
[0047] In an embodiment, the extruder 200 can include a servo-hydro motor 210 operatively coupled to the first end of the screw 208. The servo-hydro motor 210 can be configured to rotate the screw 208 within the barrel 202 about a longitudinal axis of the barrel 202 and also linearly move the screw 208 between a first position and a second position. Referring to FIG. 2C, at the first position, a second end, opposite to the first end, of the screw 208 remains away from the second end of the barrel 202. Further, referring to FIG. 2D, at the second position, the second end remains at the second end of the barrel 202. Accordingly, rotation of the screw 208 at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel 202 can allow a predefined volume of the molten material be to be transferred from the first end toward the second end of the barrel 202 at a predefined pressure. In addition, the linear movement of the screw 208 at a predefined linear speed and a predefined frequency within the barrel 202 can cause the predefined volume of the molten material (parison) to be extruded from the die-head 206 into the die-mold at a predefined flow rate and frequency.
[0048] In an embodiment, the machine 300 can further include a blow pin and a pumping unit) or blower) (collectively designated as 206, herein) configured on the frame. The machine 300 can be configured to enable the insertion of the blow pin 306 within the cavity of the die-mold upon filling of the molten material within the die-mold by the extruder 200. The die-mold can be closed once the molten material is extruded within the die-mold, and then the blow pin 306 can be inserted within the die-mold. Further, the pumping unit or blower can enable the blow pin 306 to blow a fluid such as air or vacuum at a predefined pressure within the cavity filled with the molten material to form the article within the die-mold. Later, the die-mold can be configured to be opened or separated into two or more parts upon curing or cooling of the article to allow separation of the formed article from the die-mold.
[0049] In an embodiment, the machine 300 can include a controller operatively coupled to the heating element, the servo-hydro motor 210, and the blow pin 306 and blower assembly. The controller can include one or more processors coupled to a memory storing instructions executable by the processors, which can cause the controller to perform one or more designated operations. The machine 300 can further include a control panel comprising a display and input buttons, that can allow a user to set the predefined temperature for the heating element, the predefined rotational speed, and the predefined direction of rotation of the screw 208 or the servo-hydro motor 210, and the predefined linear speed and the predefined frequency at which the screw 208 is to be moved between the first position and the second position.
[0050] In an embodiment, the controller can be configured to adjust the temperature of the heating element at the predefined temperature to melt the material received at the first end of the barrel 202. The controller can further actuate the servo-hydro motor 210 to rotate the screw 208 at the predefined rotational speed and in the predefined direction about the longitudinal axis of the barrel 202 based on the volume of the molten material and the pressure at which the molten material is to be to be transferred from the first end towards the second end of the barrel 202. Further, the controller can actuate the servo-hydro motor 210 to linearly move the screw 208 at the predefined linear speed and the predefined frequency between the first position and the second position within the barrel 202 based on the volume of the molten material and a flow rate at which the molten material (parison) is to be extruded from the die-head 206 into the die-mold. Furthermore, the controller can also control the insertion of the blow pin 306 within the cavity of the die-mold and further actuate the blower to blow air or fluid within the die-mold, to form the article. Finally, the controller can actuate the clamping assembly 304 using a separation means to remove the die-mold from the machine 300 and separate the article from the die-mold.
[0051] Referring to FIG. 4, a blow molding method 400 is disclosed. The method 400 can involve the components associated with the machine of FIGs. 2A to 3C. Method 400 can step 402 of supplying a material into the hollow barrel, where a first end of the barrel is fluidically connected to a die-head. Method 400 can further include step 404 of heating the material at a predefined temperature within the barrel using the heating element to melt the material such that the molten material is formed at the first end of the barrel.
[0052] Further, method 400 can include step 406 of rotating the screw at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel based on the volume of the molten material and the pressure at which the molten material is to be transferred towards the die-head. Furthermore, method 400 can include step 408 of linearly moving the screw at a predefined linear speed and a predefined frequency within the barrel based on the volume of the molten material and a flow rate at which the molten material is to be extruded from the die-head into a die-mold. As a result, molten material (parison) is extruded into the die-mold via the opening of the die-mold, which can be further closed.
[0053] In an embodiment, method 400 can further include step 410 of inserting the blow pin within a cavity of the die-mold upon filling the molten material within the die-mold, followed by blowing, via the blow pin, a fluid or air at a predefined pressure within the cavity filled with the molten material to form the article within the die-mold. Finally, method 400 can include step 412 of opening the die-mold upon curing or cooling of the article to allow separation of the formed article from the die-mold.
[0054] In an implementation, the machine 300 can be initiated with a preliminary startup sequence, activating the heating process to attain the optimal temperature for the raw material. Subsequently, the raw material is introduced into the machine hopper 204. The machine 300 undergoes tuning to align with the specific heating requirements of the raw material. Parameters are configured using the control panel to match the characteristics of the intended article or mold. The servo-hydro motor 210 can be calibrated to establish the predefined flow and pressure, driving the front-and-back movement of the screw 208 within the barrel 202 for extruding the parison. Upon achieving the desired molten state, the parison can be extruded directly through the die-head 206 via the reciprocating motion of the screw 208. The specialized die-head 206 ensures precise and rapid formation of the parison.
[0055] Further, the die-mold can close around the parison, and the blow pin 306 can be inserted into the cavity, introducing air to shape the final article. After the blow cycle concludes, the die-mold can be opened, allowing access to the finished article. The article can be either dropped or ejected, or it can be subjected to additional automated processes such as deflashing, conveying, or leak testing based on the processor's requirements. This cycle repeats continuously throughout the machine 300's operation.
[0056] It is to be appreciated that the overall blow molding process is optimized by employing a single servo hydro motor 210, eliminating the need for a gearbox, hydraulic motor 210, chain pulley, or AC drive as used in conventional machines of FIG. 1A and 1B. This not only enhances control for the controller but also reduces the machine’s connected load by 30-60%. The controller gains flexibility in adjusting parameters to achieve the desired weight, whether low or high and can use different raw materials in the same machine. Additionally, this setup experiences lower wear and tear, ensuring high process efficiency. The process offers exceptional precision, accelerated extrusion, consistent weight with minimal tolerance (+/- 1 gms), stage-wise parison for effective wall thickness control, ultra-low weight production, enhanced overall process efficiency, and substantial power savings. Notably, the achieved accuracy parallels those existing solutions without the need for heavy investments in components, resulting in significant capital cost savings and reduced additional power load typically associated with parison control systems.
[0057] In the present invention, the weight of the article can be easily changed via the method of reducing the die-head gap and controlling the parison shot through the screw 208. The screw 208 refills the desired weight within the barrel 202 by moving backward and keeps ready for the next shot. Once ready, the screw 208 can create high pressure and extrude the parison through the gap to form the parison. This extrudes the molten plastic rapidly and with continuous high pressure to obtain the parison irrespective of the thickness. The flow and pressure ensure that no swirling happens on the die-head 206 and enable the machine 300 to achieve the desired ultra-low weight article, thereby overcoming the issues pertaining to the conventional machines.
[0058] In addition, the process is controlled via the servo hydro motor 210 with the ability to control the flow and pressure, which makes the process efficient, and easy and eliminates transmission loss, in comparison to conventional machines. For example, conventional machines can have a connected load of 28KW with an average power consumption per hour of 20KW. However, the proposed machine 300 can have a connected load of 20.4 KW with an average power consumption per hour of 14 KW.
[0059] Further, in the proposed machine 300, the article thickness can be controlled via the screw 208 itself by alternating the stages of the parison into either 3 or 5 stages. The rotating and moving screw 208 refills the amount of raw material required for the shot. The screw 208 stores exactly the required quantity of the material and eject the material either as a single shot (parison) or can be varied in multiple shots continuously of either the same or different shot weight in the stages of extrusion. This is achieved by alternating the pressure and flow from the motor 210. Thus, delivering a consistent article every time with the lowest tolerance of +/- 1 gm, is better compared to the conventional machine 300s having tolerance on the article between +/- 5 gm.
[0060] Further, in the proposed machine 300, the screw 208 acts on a FIFO principle. Only the required quantity of the shot (parison) is stored for extrusion in the shot area of the screw 208. The screw 208 refills periodically after each shot and ejects the material in FIFO action. To change the color, the machine 300 needs to add the new raw material with color in the hopper 204, and by the 4-5th shot the machine 300 delivers the new color. Only if the machine 300 uses a high-carbon material or color, the user may have to open the components otherwise the machine 300 does the changeover online without having to stop or purge the components. This provides immense savings in raw material cost, and time and enhances the versatility of the machine 300.
[0061] Furthermore, since there is just 1 single servo-hydro motor 210, the circulated oil to for cooling the extruder 200 is exposed to less frictional heat. This benefits the oil to remain at ambient temperature and hence reduces maintenance costs for the machine.
[0062] Thus, this invention overcomes the above drawbacks, shortcomings, and limitations associated with existing blow molding machines, by providing an improved and streamlined approach solution in the form of the proposed machine and method to enhance efficiency, reduce resource consumption, and minimize maintenance requirements, thereby contributing to a more sustainable and cost-effective blow molding process.
[0063] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0064] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0065] Moreover, in interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[0066] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are comprised to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art. , Claims:We Claim:
1. An extruder (200) for a blow molding machine (300), the extruder (200) comprising:
a hollow barrel (202) having an open first end fluidically connected to a hopper (204), wherein the hopper (204) is configured to receive and supply material at the first end within the barrel (202);
a heating element configured at the first end of the barrel (202) to heat and melt the material supplied via the hopper (204);
a die-head fluidically connected to a second open end of the barrel (202);
a screw (208) extending longitudinally through the barrel (202) such that a first end of the screw (208) remains at or at least partially outside of the first end of the barrel (202), wherein the screw (208) is rotatably and linearly configured within the barrel (202),
wherein rotation of the screw (208) within the barrel (202) enables movement of the molten material from the second end towards the second end of the barrel (202) or the die-head and wherein linear movement of the screw (208) towards the second end of the barrel (202) enables extrusion of the molten material via the die-head.
2. The extruder (200) as claimed in claim 1, wherein the extruder (200) comprises a servo-hydro motor (210) operatively coupled to the first end of the screw (208), wherein the servo-hydro motor (210) is configured to:
rotate the screw (208) within the barrel (202) about a longitudinal axis of the barrel (202); and
linearly move the screw (208) between a first position and a second position,
wherein at the first position, a second end, opposite to the first end, of the screw (208) remains away from the second end of the barrel (202), and
wherein at the second position, the second end remains at the second end of the barrel (202).
3. The extruder (200) as claimed in claim 1, wherein the extruder (200) comprises a controller in operatively coupled to the heating element and the servo-hydro motor (210), wherein the controller is configured to:
adjust temperature of the heating element at a predefined temperature to melt the material received at the first end of the barrel (202);
rotate the screw (208) at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel (202) based on the volume of the molten material and the pressure at which the molten material is to be to be transferred from the first end towards the second end of the barrel (202); and/or
linearly move the screw (208) at a predefined linear speed and a predefined frequency within the barrel (202) based on the volume of the molten material and a flow rate at which the molten material is to be extruded from the die-head into the die-head (206).
4. A blow molding machine (300) comprising:
an extruder (200) comprising:
a hollow barrel (202) having an open first end fluidically connected to a hopper (204), wherein the hopper (204) is configured to receive and supply material at the first end within the barrel (202);
a heating element configured at the first end of the barrel (202) to heat and melt the material supplied via the hopper (204);
a die-head fluidically connected to a second open end of the barrel (202);
a screw (208) extending longitudinally through the barrel (202) such that a first end of the screw (208) remains at the first end of the barrel (202), the screw (208) rotatably and linearly configured within the barrel (202), wherein rotation of the screw (208) enables movement of the molten material from the second end towards the second end of the barrel (202) or the die-head and wherein linear movement of the screw (208) towards the second end of the barrel (202) enables extrusion of the molten material via the die-head; and
a die-head (206) having an opening and an inner cavity having a predefined profile based on a shape of an article to be fabricated,
wherein the machine (300) is configured to securely position the die-head (206) below the die-head of the extruder (200) such that the linear movement of the screw (208) towards the second end of the barrel (202) enables extrusion of the molten material via the die-head into the die-head (206).
5. The blow molding machine (300) as claimed in claim 4, wherein the extruder (200) comprises a servo-hydro motor (210) operatively coupled to the first end of the screw (208), wherein the servo-hydro motor (210) is configured to:
rotate the screw (208) within the barrel (202) about a longitudinal axis of the barrel (202); and
linearly move the screw (208) between a first position and a second position,
wherein at the first position, a second end, opposite to the first end, of the screw (208) remains away from the second end of the barrel (202), and
wherein at the second position, the second end remains at the second end of the barrel (202).
6. The blow molding machine (300) as claimed in claim 5, wherein the machine (300) comprises a controller that is operatively coupled to the heating element and the servo-hydro motor (210), wherein the controller is configured to:
adjust temperature of the heating element at a predefined temperature to melt the material received at the first end of the barrel (202);
rotate the screw (208) at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel (202) based on the volume of the molten material and a pressure at which the molten material is to be to be transferred from the first end towards the second end of the barrel (202); and/or
linearly move the screw (208) at a predefined linear speed and a predefined frequency within the barrel (202) based on the volume of the molten material and a flow rate at which the molten material is to be extruded from the die-head into the die-head (206).
7. The blow molding machine (300) as claimed in claim 6, wherein the machine (300) comprises a blow pin (306) configured to be inserted within the cavity of the die-head (206) upon filling of the molten material within the die-head (206), wherein the controller enables the blow pin (306) to blow a fluid at a predefined pressure within the cavity filled with the molten material to form the article within the die-head (206), and
wherein the die-head (206) is configured to be opened upon curing or cooling of the article to allow separation of the formed article from the die-head (206).
8. A blow molding method (400) comprising:
supplying (402) a material into a hollow barrel (202), wherein a first end of the barrel (202) is fluidically connected to a die-head;
heating (404) the material at a predefined temperature within the barrel (202) to melt the material;
rotating (406) the screw (208) at a predefined rotational speed and in a predefined direction about the longitudinal axis of the barrel (202) based on the volume of the molten material and the pressure at which the molten material is to be to be transferred towards the die-head; and
linearly (408) moving the screw (208) at a predefined linear speed and a predefined frequency within the barrel (202) based on the volume of the molten material and a flow rate at which the molten material is to be extruded from the die-head into a die-head (206).
9. The method (400) as claimed in claim 8, wherein the method (400) comprises the steps (410) of:
inserting a blow pin within a cavity of the die-head (206) upon filling of the molten material within the die-head (206);
blowing, via the blow pin, a fluid at a predefined pressure within the cavity filled with the molten material to form the article within the die-head (206).
10. The method (400) as claimed in claim 9, wherein the method (400) comprises the steps (412) of opening the die-head (206) upon curing or cooling of the article to allow separation of the formed article from the die-head (206).