MXPA97008629A - Dice of ja bar - Google Patents

Abstract

The present invention relates to blocks of soap die having a reduced aspect ratio, but which can carry the same number or more identical cavities as a conventional given block, or which have the same aspect ratio and can carry minus one more identical cavity. This can be achieved by placing a larger cavity axis at an angle of 1º to 90º from a major axis of the datum block.

Description

SOAP BAR DICE FIELD OF THE INVENTION The present invention relates to the so-called die blocks that are used in the process of stamping bars, that is, the process in which soap bars and / or detergent are stamped from extruded ingots of material. More particularly, it refers to dice blocks in which either (1) the aspect ratio of the block is decreased compared to a conventional die block; or (2) the die block has the same aspect ratio as a conventional comparative block, but contains at least one more cavity than such conventional die block (ie, due to the way in which the cavities form angle and / or due to the reduced total area between the cavities). Although it is usually the number of cavities (which are usually identical in terms of their size and shape) that fits over a given die block, which applicants refer to as "capacity," more generally, capacity refers to to the global area on the block that is dedicated to the "space of the cavity" as opposed to the "space of the non-cavity". / BACKGROUND OF THE INVENTION Traditionally, soap bars are stamped from ingots of extruded material in order to achieve bars of attractive and uniform appearance. Bar stamping can be achieved by using a pair of opposed die members that physically come together (i.e., in a compaction step) to stamp the bars. Instead of pressing the opposite die members into an individual cavity, the die may be an extended die having a plurality of cavities thereon. An extended die that has more than one cavity is generally designated as a "die block" (although in theory, a die block may comprise a cavity). The length of a die block is usually set by the length of the press against which the die block is mounted. Because, as is a practical matter, the press is purchased as a normal-sized part from a supplier, the length of a conventional press and a conventional die block are generally fixed. It is generally believed that the die cavities on a die block must be molded or machined in such a way that an imaginary line (major axis) that crosses transversely the major axis of the die cavity (generally defines the length of the cavity) must be parallel to the major axis through the die block (defining the length of the die block). Furthermore, it has generally been believed that the ends of the two adjoining cavities (defined by the "end" or extremities of the major axis) must have a separation distance between them not less than a specified minimum value. This, from the start, increases the total area of the die block between the cavities and does not define the space of the cavity. It also increases the percentage of the total die block area destined for a space that is not cavity in opposition to the space of the cavity (that is, the capacity of the die block decreases). It has been believed that the minimum separation distance between the die cavities is especially critical, because when a nugget (a "trunk" refers to the long extruded pieces after extrusion and after cutting, an ingot is referred to to the pieces after cutting, and a bar refers to the piece after it has been stamped from the ingot of soap that is about to be stamped placed between the dice blocks that define and form the cavities, has believed that a certain amount of soap (volume of soap from the nugget) is required to fill the cavities. If the cavities are too close together, it has been thought that the cavities of the soap are not filled and that the bars thus made are imperfect.

Actually, a specification sheet typical of Bi nacchi and Company, is to say, a company that makes conventional soap presses used in bar stamping that refers to "A" and "B", where "A" is the separation between the bars and "B" the width of the bar at the edges, that is, the width of the cavity at the end of the major axis (this can be an individual point, for example, if the bar is one the i pse) declares B becomes larger, (ie, from B = 0 to B = 0 to 8 to B = 8 to 1 5, etc.), the separation between the cavities A of they must also grow older. Therefore, there is a clear teaching that comes from moving the separation by the manufacturer of the press used in the industry. In turn, this means that more than the die block defines an area between the cavities, and less than the die block defines the cavity area itself. Again, this defi nition results in less capacity, where the capacity is the area used for the cavity space, not the non-cavity space area (such as the cavity separation). Although separating the cavities additionally has been desirable to ensure that the die cavities are completely finished, the additional area between the cavities (reduced capacity) also means that there will be additional re-elaboration (ie, the amount of soap not used to fill the cavities and that must be sent back to the soap maker to be "re-processed" before being recycled once more into the stamping machine). Re-working is also known in the art as "burr". Any burr or re-elaboration that must be sent back to the processor means that the processor, who has a limited capacity, is fed with less soap mixture from any additional upstream in the processor and this in turn means that the Performance of finished rods is reduced. Less re-working (due to less separation between the ends of the cavities) also offers additional advantages. In some formulations, excessive processing reduces extrusion and stamping performance. Less reworking thus obviously improves the extrusion and stamping of the bar. In addition, minor re-working also means lower ingot temperatures which can lead to improved stainability. Finally, for the fluted bars, the reduced reworking results in an improved flute. Despite the advantages that result from less re-processing and despite the fact that moving the ends of the cavity closer together may result in the placement of more cavities in a given fixed area (ie, increased "capacity") or similarly, the same number of cavities in a small area (that is, if the lower aspect ratio dice blocks are used); because the technique teaches the disadvantages of translated spacing between the ends of the cavities (and therefore, less total area), the die blocks containing such closely aligned cavity ends are not known. With respect to the angular movement of the dice (in such a way that the major axis through the cavity is not parallel to the major axis of the dice block), the angled dice have been used to improve the flute of the fluted bars . However, it has never been previously recognized and, therefore, none has previously attempted to angle the dice with the purpose of: (1) increasing the number of cavities, preferably identical cavities, per fixed block length of block ( increasing capacity); or (2) maintaining at least the same, preferably increasing, number of cavities in a smaller die block length with respect to the larger die block that has not been angled or more closely spaced between the cavity ends (in other words, increasing the capacity of the identical cavities in size and shape). Unexpectedly, applicants have found that (1) if the die / bar cavities are angled such that the major axis running through the cavity or bar (generally defining the length of the cavity) is angled in distance from the major axis of the die block and / or (2) if the area between the cavities is reduced (in fact, the area of the entire die block is reduced), for example, when the cavities are joined together , then it is possible to either (1) increase the number of die cavities (at least one) as compared to a fixed aspect ratio die block; or (2) maintaining the same number of cavities on a die block, of reduced aspect ratio; or (3) increase the number of cavities on a die of reduced aspect ratio die. Therefore, the invention can more generally be defined as die blocks with an increase in capacity ratio (area of cavity space) with respect to the die block aspect ratio (ratio of the long surface area of the block with respect to the length of the short side of the block) compared to a conventional die block.

SHORT DISC RI PCI OR N D I NED ION Accordingly, the invention provides a conventional die block modified by increasing the ratio of the capacity (area of cavity space) of such die block to the aspect ratio (ratio of the long surface of the block to the length of the short side) of such die block.

In addition, when the block area of the total die between the cavities, and that does not define the cavities themselves, is reduced, the amount of re-processed soap is significantly reduced (ie, because more soap / ingots are being stamped on bars). In addition, applicants have found that the additional cavity (for example, 5 cavities instead of 4 in the case of the examples shown below) is filled using the same volume of extruded ingot. It was particularly surprising to find that the total area of the die block not used to define the cavity (for example, when approaching the gap between the cavities) can be reduced while at the same time filling the additional cavity using the same volume of soap. In one embodiment, the present invention relates to either (1) a die block of fixed aspect ratio (generally determined by the length of the press commercially available from the manufacturer) on which one or more preferably additional identical cavities can be adjusted or (2) a reduced aspect ratio die block containing the same or a larger number of cavities (of identical size and shape) than a conventional die block, wherein the conventional block does not have angled placement or has no reduced spacing between the ends of the cavity and, consequently, no reduced overall area defining non-cavity areas on the die block. As is to be noted, the increased capacity (defined by more cavities over the same length of the given block; or the same or a larger number and shape of cavities over a smaller block length) is obtained either by (a) placing the major axis of the cavity at an angle (eg, 1 or 90 °) away from the axis greater of the die block and / or (b) reducing the spacing between the ends of the two adjacent cavities. Preferably, the major axis through the cavities should be angled from the major axis of the die block at an angle of 1 or 90 °. In some embodiments, the angle may be 10 ° to 60 °, more preferably 20 ° to 50 °. The cavities can be angled even if additional cavities are not added (ie, to reduce the separation between the "non-cavity" areas and thereby obtain the re-elaboration benefits discussed below). It should be noted that the optimum angle orientation depends on the shape of the bar and, for example, the optimal orientation for some bars is 90 ° while for others it can be 20 ° -70 °. In addition, optimum orientation can be achieved either by adding more cavities for a given space or by reducing the area / re-working between the cavities. It should be understood that the die blocks may contain more than one row of cavities. It should also be understood that some cavities can be placed at an angle while others can not. There may be more than one row of cavities where, in each case, for example, the major axis is still parallel to the major axis of the die block. This is particularly useful in the manufacture of small bars or tablets such as those used, for example, in hotels. In a further embodiment of the invention, the invention relates to a method for increasing the number of cavities in a die block having the same aspect ratio as a conventional die block; or to maintain the same number of identical cavities or to increase the number of cavities in a reduced aspect ratio die block whose process comprises either or both of: (1) placing in angle or the major axis through the cavities an angle of 1 ° -90 °. (In some embodiments, 10 ° to 60 °, most preferably 20 ° to 50 °) from the major axis through the die block (ie, the length "A"); and / or (2) reducing the spacing between the cavities (and the overall area of the entire die block). In yet another embodiment, the invention relates to a method for reducing re-working ("flash") during the process of stamping soap bars, which method comprises using a conventional die block that has been modified to reduce the area between the cavities (for example, between the edge of a cavity and the next cavity) placing the cavities between 1 ° and 90 ° at an angle. In some embodiments of the invention, it is preferable to angle the cavities at 10 ° to 60 °, more preferably 20 ° to 50 ° from the major axis of the die block. On the other hand, it should be understood that, in some embodiments of the invention, the preferred angle placement is, for example, 90 °.

B REVE DESC RI PCIÓ N OF THE B UJOS Figure 1 shows a typical operation fertilizer stamping apparatus including the operating positions of the reciprocating and rotating stamping die components of the die block containing the die cavities. The figure shows dies that are commonly used that have four cavities and that have the major axis through the cavities parallel with respect to the major axis through the pl just given. Figure 2 shows an ingot elevator that is used to raise the idle to the reciprocating and rotating stamping dies where they are configured. Again, this figure uses the die currently used with the major axis through the four die cavities (4) parallel to the major axis through the die block. Figure 3 is a view of a reciprocal die positioned at an angle in accordance with an embodiment of the invention wherein the major axis through the cavity or bar is positioned at an angle at 25 ° -30 ° from the major axis of the block of die It can be seen that the die now contains five cavities on the same length of the die, that is, a die of 50.8 cm (20 inches) (length of the die controlled by the length of the press available from the manufacturer). It is to be noted, that the figure shows half of the reciprocal die of the dice. The jet ejectors have been erased from this figure. Figure 4 is a view of a conventional rotary die, in which the major axis of each cavity is parallel to the major axis of the die block and the distance of separation between the adjacent cavities is in line with the teaching of the manufacturer of machine. Figure 5 is a typical die block where the aspect ratio is defined as the ratio of the length of the die block, A, to the width B. The aspect ratio of each cavity is defined as the ratio of the length "a" with respect to the length through the cavity "b". A conventional die is one in which the major axis of the cavity a is parallel to the major axis of the die block A.

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to die blocks in which more cavities are introduced per linear length of unit of the die block or the same number of cavities are present in a reduced length of the die block. Therefore, there is an increase in the capacity ratio (area on the block dedicated to the "cavity space") with respect to the aspect ratio of the die block. In general, the stamping surface or area of a die block is generally defined by its aspect ratio. The aspect ratio of the die block is the ratio of the long side of the block (usually the block is rectangular and the long side defines the lengths of the block) with respect to the short side (it generally defines the width of the surface area). Therefore, the aspect ratio is A / B as seen in Figure 5. In a "conventional" die block, the major axis of the cavities machined or molded onto the blocks (defined as "a" in the Figure 5) is parallel to the major axis of block A. In addition, the conventional die block will have a fixed number of cavities of defined size and shape constrained by the following two factors: (1) the overall length of block A in such a way that , for a given length "a" of the cavity, only a fixed number of cavities will be adjusted; and (2) the separation between the edges of the two adjacent cavities. It will be appreciated that as the spacing between the adjacent cavities is reduced, the total area of the die block between the cavities (and more generally, the non-cavity area over the entire block) is reduced. During the stamping process, it is this area that defines what is not a cavity, what produces the "burr" or re-elaborated (soap sent back to the processor to be "re-made"). In general, it should be noted that, it is believed in the art that a defined volume of ingots is required to fill the cavities during stamping and that, therefore, the total area of the space defining what is not cavity should be maintained at a certain minimum level to ensure filling adequate cavities. Therefore, although the reduced re-elaboration is beneficial for a number of reasons, described later, the technique does not appreciate that this should or could be achieved by reducing the spacing between the cavities. The present invention not only unexpectedly realizes that great benefits are obtained by using an "unconventional" die block (ie, with dice placed at an angle and less area than is not a total cavity), but such dice may be prepared. Contrary to the teachings and beliefs of the art, the invention appreciates that the spacing between the individual cavities can be reduced (the technique teaches that a minimum separation is required) and that there is no sacrifice in obtaining solid bars (ie the cavities). they are adequately filled even if there is less area that is not cavity, due to the placement at an angle and / or the approach of the cavity). Specifically, in one embodiment, the invention relates to (1) a die block that has the same aspect ratio as a "conventional" die block (ie, one in which the major axis through the cavities) a "is parallel to the major axis" A "of the die block but that contains one or more additional cavities (preferably of identical size and configuration) as the conventional die block or (2) a die block that has a relationship of reduced aspect (the ratio of A / B is smaller) than a "conventional" die block, but containing the same number or more cavities as the conventional die block. In the second definition, the solictors state that within a die block that has a reduced aspect ratio of A / B, it is possible to put the same number or more identical cavities as in a given block that has a ratio of bigger aspect Therefore, there is an increase in the capacity ratio with respect to the aspect ratio of the die block. By adding more cavities to a fixed block length or the same number or more identical cavities to a smaller block length, it means in effect that the ratio of the area occupied by the space of the cavity (capacity) to the The aspect ratio of the die block will be greater. It also means that there will be minor re-elaboration (since there is less area that is not cavity and the re-elaboration can be defined by the excess of soap produced as a burr outside the area that is not cavity, when the ingot of soaps is stamped or added). Another way of expressing this is that, for a given ingot volume, more soap is used to fill the cavities than is produced in the form of flash as re-processed. It should be understood that the concept of ingot volume can not be defined cleanly. In some cases, slightly more ingot volume may be used, but, due to the additional bar or bars produced, there is a global proportional gain. Therefore, perhaps it is more correct to say, that whether the same volume of ingot is used or more or less, the use of dice placed at an angle allows a reduction in the volume of the ingot per tablet (ie, more tablets are made for a given length or volume). The reduction of re-processing (there is less volume not used) has significant advantages. The additional re-elaboration would normally be sent back to the processor to be re-worked. Because the processor itself is of a limited capacity, the larger the reprocessing, the lower the final product. Therefore, the invention allows more rods to be made and results in tremendous economic benefits.

The placement of at least one more cavity (improved capacity) on a die block that has the same aspect ratio as a "conventional" die block, or of an equal number (or more) of identical cavities on a block of The smaller aspect ratio can be achieved by placing the cavities at an angle or by reducing the "non-cavity" space as discussed above. The placement in angles of the cavities and the reduction in the separation do not have to work independently. In fact, the placement in angles of the cavities can itself be responsible for the reduction in the separation between the cavities (and therefore, the "total non-cavity" area reduced). The spacing can be reduced, however, including use if n angled placement. In the prior art, it has been believed that the spacing between the cavities can be from, for example, 7 to 1 2 millimeters (see the specifications of Bi nacchi), while, if the cavities placed at an angle of the present invention are used. , for example, the separation can be reduced to 0 μm (for example, where the edge of a cavity is on the same tangent as the edge of the second cavity placed at an angle) and can certainly be less than 7 mm, for example , preferably 0 to 6 mm, more preferably 1 to 5 mm. This is a critical difference on the technique that suggests, on the contrary, that as the width of the bar increases, the spacing between the bars must be increased. This technique comes from a manufacturer of soap presses whose equipment is widely used in the soap bar industry. The bars that are stamped according to the present invention can, for example, be a traditional fatty acid soap bar. Preferably, however, the bars of the invention are not detergent bars that are not soap bars. In such bars, the soap fatty acid is replaced with milder surfactants such as, for example, sodium cocoisethion (see, eg, US Pat. No. 2,894,912 to Geitz, incorporated by reference in the present application) or alkyl ether sulfonates. See also U.S. Patent No. 4,695,395 to Caswell, et al. , incorporated herein by reference in the present application. Referring now to Figure 1, applicants have shown a typical stamping apparatus. Typically, the "press" refers to the piece 1 similar to a long "rolling pin" on which the rotary stamping half of the die 3 is mounted through the rear plate 2 of the rotating die. More particularly, the press is divided into two flat areas 4 on which the rotating dies 3 are mounted.

The die consists not only of the die 3 of rotary stamping, but also of the other half of the die, the so-called given reciprocal. In the operation, the reciprocating dice move back and forth during the so-called compaction or pressing step to stamp the ingot between the reciprocal and rotational die halves. After compaction, the rotating die is rotated 1 80 ° in such a way that another rotating die 3 is fixed to undergo compaction while, at the same time, the already stamped rods are removed by means of the fastening cups 6. through a demolding plate 7. The demolding plate removes the soap that does not fill the cavities (which is called "burr") and the flash is recycled to a processor as discussed in the above. The die of the invention containing the cavities of the die placed at an angle is used in place of the die 3 of rotary stamping and the reciprocal die 5 and, as noted, the size will be restricted by the size of the planar areas 4 which is mounted. Figure 2 refers to what is known as the lug elevator 22 that is used to elevate the lugs for stamping. In the figure, the elevator 22 is designed to be nested in the notches found in the reciprocal die 5.

Figure 3 is a figure of the die of the invention, having five cavities on the same length where previously there were 4. These particular cavities are designed to stamp a typical Dove-shaped bar although, it will be understood, that the cavities can be cut in various forms, and the forms are not limited in any way. It will be noted that the dies of the invention can be any die known in the art, including those that are cooled by methods known in the art and / or those coated with elastomers (coated sheets or dies). The invention will now be illustrated by the following non-limiting examples.

EXAMPLE 1 A bath cube test was performed with 5 cavities placed at an angle (as shown in Figure 3) instead of 4 cavities in the horizontal orientation to (1) evaluate the quality of the bar; (2) to measure the reduction of re-elaborated soap; and (3) to determine the size and shape of the proper ingot. Surprisingly, it was found that the ingot volume did not have to be increased. The size and shape of the existing ingot were able to fill the die cavities and produce bars of quality equal to the current high standards. In addition, with one die, five bars were stamped per machine cycle instead of the current four. Finally, because the same volume of ingot can be used while reducing the distance between the cavities, a significant reduction was obtained in the re-elaboration as it is observed later: Weight of ingot Weight of the bars Re-elaborated Existing dice 839 g 546 g 35% Dice placed at an angle 839 g 682.5 g 19% This represents a tremendous reduction of 46% in the re-elaboration. Ingots were slightly contoured, height 5.08 cm (2") x width 3.5 cm (1 3/8") with flat top and bottom 3.0 cm (1 3/16") x 44.5 cm in length (1 7 1 / 2"). The die space was 0.0203 cm (0.008").

Claims (8)

1. A conventional die block, modified by increasing the ratio of the capacity of such die block to the aspect ratio of such die block.

2. The die block according to claim 1, modified in such a way that it is selected from the group of: (a) dice blocks having the same aspect ratio, but at least one more cavity than the conventional die block; and (b) dice blocks having a smaller aspect ratio, but at least the same number of cavities, than such conventional die block, such conventional die is a die in which the major axis running through the cavities is parallel to the major axis of such conventional die.

3. The die block according to claim 2, characterized in that the increased number of cavities on a block of aspect ratio identical to a conventional block; or maintaining the same number or more cavities in a block of reduced aspect ratio, is achieved by placing an angle at a greater angle through the cavities molded or machined on the die at an angle of 1 ° to 90 ° from a major axis of the die block.

4. The block according to claim 3, characterized in that the angle is from 10 ° to 60 °.

5. The block according to claim 3, characterized in that the angle is from 20 ° to 50 °.

6. The block according to claim 2, characterized in that the increase in the number of cavities with respect to a conventional die block, or maintaining or increasing the number of cavities in the lower aspect ratio block is achieved by decreasing the area that is not cavity of the die block.

7. A method for increasing the number of cavities in a die block having the same aspect ratio as a conventional die block, or for maintaining the same or more identical cavities in a reduced aspect ratio die block, the process comprises at least one of (i) angulating the major axis through the cavities at an angle of 1 ° to 90 ° from the major axis through the die block; and (ii) reduce the non-cavity area of the die block.

8. The method for reducing the re-elaboration of the process of stamping soap bars or detergents whose method is characterized in that it comprises using a conventional die block that has been modified by reducing the non-cavity area of the block when the shaft is angled greater through the cavities at an angle of 1 ° to 90 ° from the major axis through the die block.