Improved method and apparatus for constructing integral, double-walled vessels.

Abstract

To provide a method and a device suitable for mass production of a double wall container consisting of two containers extending in the same direction and having an air gap between the containers.SOLUTION: A double wall container is molded by a drawing-blowing as a unit from a thermoplastic material. A thermoplastic cylindrical blank is formed, then adjusted thermally. Then, the thermally-adjusted cylindrical blank is extended mechanically in a longitudinal direction and is applied with a blowing-molding by a gas pressure to the outside, thus the cylindrical blank is formed in a shape of a mold cavity set in a first dual container shape, the first container and the second container joined integrally and inseparably are molded by the drawing-blowing and both containers extend in opposite directions.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a stretch blown double wall container unitarily formed from a thermoplastic resin tubular blank. - A method and an apparatus for forming a double-walled container, the double-walled container being integrally and inseparably connected and oriented in the same direction The structure has two adjacent containers extending in a direction parallel to the surface of the container, and an air gap is provided between the two adjacent containers. The present invention specifically relates to an integral casing having very thin walls and a highly uniform wall thickness. The present invention relates to a method and apparatus for manufacturing an inseparable double-walled container suitable for high speed mass production. [Background technology]

[0002] According to Wikipedia, a container is "a container used to hold, store, and transport objects or substances. "Basic tools consist of any device forming a partially or completely enclosed space that can be used" It is.

[0003] As used herein, the term "container" refers to a container that, by design, holds liquid and / or solid contents. Used to hold such contents, whether or not intended to hold such contents All receptacles having a hollow or concave internal structure that can be at least substantially filled The opening includes a radial axis and is arranged parallel and / or at an angle to the longitudinal axis of the vessel. and a bottom wall that substantially includes a radial axis of the container. The bottom wall refers to the completely closed bottom wall that forms the lower end of a completely closed container. or a partially closed bottom wall forming a partially closed lower edge. A partially closed bottom wall is one in which the bottom wall surface area is measured in the same radial plane. At a minimum, the partially enclosed bottom wall is substantially larger than the average side wall surface area. The thickened wall at the end of the side wall, such as the mechanical and / or hermetic joint shape of the cylindrical blank, The edge portion may be a curved edge portion.

[0004] The containers used in this application include beakers, bottles, deep dishes, water bottles, caps, carafes, tiered containers, etc. Cardboard boxes, clamshells, covers, cups, fast food containers, food containers, glass cups cups, hoods, lids, mugs, plates, pots or tumblers or for carrying liquids and / or solids Any other derivative of a container that represents a partially or completely enclosed space capable of holding bodily contents It can be said that:

[0005] As used herein, the term "cylindrical" refers to an object that is substantially tubular or cylindrical in shape. It refers to an object that is hollow in nature and substantially cylindrical in shape, which by definition means that a cylindrical object is round or This does not mean that it has to be circular. A cylindrical object may not be suitable for any particular purpose. and / or may be of any cross-sectional shape or form required depending on the vessel design, Round, circular, oval, triangular, square, rectangular or any of these geometric shapes in the lateral and / or longitudinal directions. Includes all combinations of geometric and / or non-geometric forms or shapes, but in no way Not limited to these.

[0006] As used herein, "two adjacent containers that are inseparably joined together" means Two containers extending in the same direction with an air gap between them, formed as a single unit The term "double-walled container having a structure of the same construction as that of the container itself" shall be replaced with the equivalent term "integral double-walled container". It is possible.

[0007] As used herein, "two containers that are inseparably joined together and extend in opposite directions" means The phrase "a dual container having a structure of two containers formed as a single unit" is amended to read as follows: This can be equivalently replaced with "one inseparable dual container."

[0008] As used herein, the term "blow ratio" is equivalent to "expansion ratio." Any given dimensional size of the cylindrical blank (or cylindrical slug) before blow molding can be obtained. This refers to the ratio of each dimension of the container after blow molding.

[0009] As used herein, the term "mold cavity set" typically refers to two substantial This refers to a mold having mold halves that are substantially similar, but as will be apparent to those skilled in the art, this may include A mold cavity set shall not be considered as being limited to only two mold components. The number of integral and / or separate parts that make up a mold cavity set is arbitrary. It can be said that:

[0010] The term "air" as used herein refers to the above mentioned superatmospheric and / or subatmospheric pressure systems. This refers to the gas used as part of the It will be apparent to those skilled in the art that the present invention should not be considered as a gas or gas mixture suitable for such use. There are many possible combinations of gases.

[0011] Every year, thousands of low-cost containers suitable for mass production are produced around the world. Therefore, for low-cost containers mass-produced from thermoplastic materials, the question of low-cost manufacturing is Subjects include, but are by no means limited to: Low-cost heat-deformable synthetic resin Thin walls / light empty weight Fast production speed -Reduces logistics costs by enabling small cell manufacturing facilities to be located adjacent to distribution centers Small production line footprint for minimal cost · Manufacturing method based on primary processing High reusability Maximize stackability to minimize logistics and storage costs - Fewer sub-component parts Fewer manufacturing steps.

[0012] Currently, nearly all mass-produced containers are single-walled in nature. The main reason for this is that current manufacturing The process is not capable of producing an integral double-walled container or Any currently available manufacturing process capable of producing This becomes the unit manufacturing cost.

[0013] For example, the current method of manufacturing thermoplastic cups is by thermoforming, which uses pre-treated thermoplastic A flat sheet of thermoplastic material is heated to the softening temperature of the thermoplastic, but usually not above its melting point. The flat sheet is then pressed into a container-shaped mold by applying gas pressure and / or mechanical stretching. Thermoforming into a cavity. This method makes it easy to fabricate single-wall structures from flat sheets. Although it is possible to form a structure, we have succeeded in fabricating a complete double-walled structure from a flat sheet. There are no known variants of the above-mentioned thermoforming process that can be used for this purpose, since At least a portion of the wall structure must effectively shrink rather than stretch during thermoforming; This goes against the basis of the process.

[0014] As another example, some bottle-shaped containers are manufactured by extrusion blow molding and are heated to above their melting point. A tube of molten thermoplastic material is extruded between a set of container-shaped mold cavities, and the Then, while still in the molten state, gas pressure is applied to force the molten thermoplastic into the cavity. The problem with mass production with this process is that the melt tube extrusion is very slow. Therefore, high production rates cannot be achieved and the final container is The problem is that this process places practical limits on how thin the walls can be. Typically, the wall thickness is well above 1 mm, which is commercially acceptable for mass-produced containers. This will result in high costs.

[0015] Two adjacent containers that are inseparably joined together with an air gap between them A one-piece, inseparable double-walled container having a structure of two containers formed as a single unit having a loop. There are numerous market-driven reasons for parity, including: These include, but are not limited to: -Fully reusable coffee cup formations · Formation of a cold cup that does not form water droplets on the outer wall - Formation of a cold cup that can extend the shelf life of beverages · Formation of containers that allow contents to remain at elevated temperatures for longer periods of time.

[0016] As an example, using a cup genre in a boundary container sector can cause burns to the user's hands. A separate heat sleeve is widely used to prevent coffee cups from Here are some typical solutions that users employ to address any of these needs: The solution is a "double-walled container with an air gap" by placing a cup inside a cup. From a mass production perspective, the solution of "putting a cup inside a cup" This option, like using a separate coffee cup heat sleeve, does not incur significant additional costs. This will increase the amount of waste generated, which will be difficult to meet any recycling requirements. However, this would be counterproductive.

[0017] Cost-effective solutions for large volumes and across all container categories Two adjacent inseparable containers are assembled together to form an air gap between them. The object of the present invention is to form an inner container having a structure formed by the above-mentioned method.

[0018] Brief description of the prior art U.S. Pat. No. 3,182,842 describes a double-walled container manufactured by extrusion blow molding. The document describes the structure of the compound, and various steps of its preparation are described in the document, which are All this is done while the container is still in the molten state. The entire double walled container is now completely formed. Only when the temperature is high enough will the thermoplastic resin cool enough below its melting point to be able to harden. The vessel is then allowed to cool.

[0019] As previously mentioned, extrusion blow molding has the disadvantages of slow production speeds and a significantly thicker walled product. Typically, even if they are used, the process is low-cost and mass-produced. This was rare, but was the mainstay of the time the patent was filed in 1963. Over the next few decades, techniques more suited to thin-walled structures were developed. Great advances have been made in blow molding manufacturing.

[0020] U.S. Pat. No. 3,612,346 discloses a method for producing a thermoformed plastic from a pretreated flat sheet. The paper describes a double-walled cup structure manufactured from a flat sheet, with a portion of the flat sheet being in the center cup portion. The recessed portion is integrally formed with an outer reverse tapered wall portion which covers at least a portion of the recessed portion.

[0021] The patent is primarily concerned with an external double-sided container to aid in the stackability of cups for vending machines. Although the patent teaches a reverse tapered section of the wall, it does not pass downwardly past the bottom wall of the central cup section. The patent discloses a cup having an extending, inversely tapered, outer double side wall. The description is based on thermoforming of cups from treated flat sheets, so The image of this cup is unlikely to be manufacturable as instructed. Under the application of heat and pressure, some areas are hot-stretched (central cup area) and at exactly the same time There are no known thermoplastics that can be heat-shrunk in other areas (the outer wall of the inverted taper). Even if such a thermoplastic resin is present, the inverse tapered outer double sidewall is not The wall thickness cannot be uniform as in the case of the casing, but rather has a large gradation in wall thickness and a decrease in radial diameter. The wall thickness increases inversely to the wall thickness of the cup, becoming thinner adjacent to the drinking lip. It is thicker at the bottom edge.

[0022] The method of teaching for thermoforming the cup from a flat sheet was found to be achievable. In the unlikely event that the resulting cup is too expensive for a mass-produced container, This is because thermoforming by itself cannot form ultra-thin cup walls, and reverse taper The gradual wall thickness of the outer double sidewall greatly influences the final empty cup weight, which This has a large impact on the unit price of the cup. A typical wall thickness for a single-walled 500ml cup for selected fast food applications is 0.35mm. The typical empty cup weight is on the order of 13 g. An integral, inseparable, reverse tapered outer double side wall is added by shrink molding from the base. This would result in a potential empty cup weight at least twice the current typical cup weight. become.

[0023] U.S. Pat. No. 3,969,060 describes a boron sputtering machine based on the deformation of a cylindrical slug of thermoplastic material. The paper describes a method for blow molding a slug. The slug is a cylindrical slug having only one open end. and is produced in a separate injection molding process. The temperature of the cylindrical slug is in the thermal softening range, but typically well below the melting point of the thermoplastic resin. After the cylindrical slug is heat-conditioned to the desired temperature, it is stretched and then pressed against the outer mold. The finished bottle product is formed by taking the cavity shape of the cavity set. Mechanical and / or gas pressure is then applied to cause the cylindrical slug to expand outward.

[0024] First taught around 1976, this process has been revolutionized in the manufacture of thin-walled bottles. When thermoplastic resins must be heated above room temperature for thermoforming, After that, the thermoplastic resin needs to be cooled to return to approximately room temperature after molding. Cooling time affects overall production speed and therefore unit cost of product. By blow molding at a temperature well below the melting point of the resin, the heating and cooling times are the same as those of the extrusion This is significantly shorter than blow molding, which greatly increases the overall production speed. In addition, thermoplastics typically stretch more uniformly below their melting point; The advent of the process has made it possible to reliably manufacture significantly thinner-walled bottles. The advantage is that the thinner the walls of the finished product, the more quickly it can be cooled to near ambient temperature. It is possible.

[0025] The advent of this process, known as "stretch blow molding," gave rise to the The process has disappeared altogether except for the production of mass-produced bottle-shaped containers.

[0026] U.S. Pat. No. 9,339,979 discloses a bi-layer thermoformed as a single piece from a thermoplastic material. A wall heat shield cup having at least one rib that maintains partial separation between the inner wall and the outer wall. A double-walled heat insulating cup having a formed cup with a sealed insulating space. There is no teaching on the cup-forming process itself other than the reference to "thermoforming." However, the patent discloses that the double-walled heat insulating cup is formed from a tube having first and second open ends. The patent discloses that the mold is formed by applying heat and pressure to an external mold. It teaches a formed cup having a wall thickness of 0.35 mm.

[0027] The heat-softened (but not melted) thermoplastic flows radially and longitudinally through the mold. When blow molding into a cavity, how far can the resin flow reliably under the application of gas pressure? It is well known to those skilled in the art that there are practical limitations as to how reliably stretching can be performed. The blow ratio limit is the ratio between the initial cylindrical blank before blow molding and the finished product after blow molding. It is believed that the expansion ratio between the heat-softened thermoplastic resin and the blown resin is three times that of the heat-softened thermoplastic resin. Before molding, it is mechanically stretched in the longitudinal direction, typically at a ratio significantly greater than 3 times. It is also well known to those skilled in the art that the thermoplastic resin can be mechanically stretched. This combination of molding followed by blow molding is the basis of modern thin-wall container manufacturing. do.

[0028] To achieve very thin walled container production, stretch blow molding is typically used rather than thermoforming. The stretch blow molding of a cylindrical blank into a blown container is used. Mechanical stretching in the longitudinal direction (here defined as the longitudinal stretch ratio LS, Here, it is calculated as L1 / L0. In this formula, L1 is the stretched length of the cylindrical blank and , L0 is the initial length of the cylindrical blank.) Gas stretching in the longitudinal and / or radial directions (herein defined as the radial stretch ratio RS) is defined as R1 / R0, where R1 is the R0 is the circumference of each initial cylindrical blank. RSmax is defined here as the maximum value of RS along the length of the cylindrical blank. Will be These two ratios are then combined to give the total stretched braid, calculated as RS / LS. The row die ratio RL can be expressed as: The maximum RL that can be calculated at any point in the can be.

[0029] When RSmax is much greater than 3, mainly due to limitations in the physical properties of thermoplastic resins, Typically container fracture occurs during blow molding, and when mechanical stretching is present, LS is always greater than 1. Therefore, to achieve feasible blow molding of very thin-walled containers, RLmax should typically not exceed 3.

[0030] In U.S. Pat. No. 9,339,979, a thermally softened cylindrical blank is mechanically stretched by blowing. -There is no teaching that the LS ratio should be 1. In the disclosed drawings, the periphery of the cylindrical blank (the two bottom walls of the cup) is fitted with cylindrical pins. The maximum circumference of the cup product after blow molding (indicated by the point H) is the maximum circumference of the cup product after blow molding (inseparably formed The RSmax is significantly higher than 3 compared to the transition region between the two cup shapes. Thus, blow molding the dual cup configuration taught is, at best, a RS This becomes very impractical due to both RLmax and RLmax being significantly greater than 3. Even if blow molding can be performed without breaking with a high probability, the resulting molded product It will be apparent to one skilled in the art that the product may not have a uniform wall thickness as shown. There are areas, such as the transition area, that may exhibit thin-wall characteristics, but not necessarily the bottom and adjacent Other areas, such as the sidewalls, will most likely be far from thin-walled in nature.

[0031] U.S. Pat. No. 9,339,979 discloses a blow molded plastic having a wall thickness of about 0.35 mm. Considering only that the cup described is a double-walled heat insulating cup, This would be at least twice as heavy as existing thermoformed single-wall cups of that volumetric capacity. However, this can be commercially expensive for mass-produced containers.

[0032] PCT / IB2017 / 056558 describes two adjacent parts that are inseparably connected to one another. Two containers extending in the same direction with an air gap between them. A method is taught for making a double walled container having a structure, and inversion of the second container forms a dual container. The process is carried out in a state where the mold is completely enclosed inside a second mold having a vessel-shaped cavity. do.

[0033] The inversion process taught in this document involves separating the first container and the second container during inversion. Pressure above atmospheric pressure is applied as a means of stability control inside a small container, but dual-container By using a second die having a vessel-shaped configuration, the second smaller mold can be formed before and during inversion. At least a portion of the mold cavity wall of the small container is adjacent to the outer wall of the second smaller container. possible.

[0034] This close proximity between the second, smaller container and the second mold cavity wall occurs before and during inversion. When the inverted second container comes into contact with the wall, it exceeds the elastic limit of the material, which causes damage to the wall. You can.

[0035] The subject of the present invention is two adjacent containers that are inseparably connected together, A unitary non-integral structure having two containers formed as a single unit with an air gap between the two containers. Some of the drawbacks associated with forming a separable double-walled container have been overcome to make it commercially viable as a mass-produced thin-walled container. The aim is to resolve this so that it becomes possible. Summary of the Invention

[0036] In a first aspect of the present invention, there is provided a method for manufacturing a container comprising: A double wall structure having two containers extending in the same direction with an air gap between the containers. To provide a method and apparatus suitable for mass production for manufacturing a container, the double-walled container being made of a thermoplastic material. First, a thermoplastic elastomer having at least one open end is stretch-blow molded into a single piece. In this case, a cylindrical blank is formed, which is a one-piece, inseparable, double-walled container that is stretch-blow molded. In order to minimize the wall thickness of both the tubular blank and the tubular blank, the RSmax of the tubular blank is substantially The blank is heated to a temperature below its melting point so that it hardens. The blank is then heated to the softening temperature of the thermoplastic material. The material is then heat-adjusted to a first heat adjustment temperature within the range of 100° C. but below the melting point. After the heat adjustment, the material is heated to a temperature significantly above 100° C. The cylindrical blank is mechanically stretched in the longitudinal direction by a rotating LS, and RLmax is less than 3, preferably A cylindrical blank is blown outward by gas pressure so that the length is on the order of 1 or less. Mechanical stretching in the hand direction and gas rolling stretching in the longitudinal and / or radial directions are performed in a coordinated and stretching manner. The combination includes a first container and a smaller second container integrally joined thereto. A stretch blow molded, integral, dual container having a structure of: a first container and a second smaller container extending in opposite directions to each other to form a dual container as an intermediate product. In order to achieve this, the cylindrical blank must be fitted to the shape of the first dual-container mold cavity set. The second, smaller stretch blow molded container is then heat conditioned. In order to achieve this, further heat conditioning may be applied and, if deemed advantageous, a small amount of the first container may be At least a portion of the heat-adjusted temperature is adjusted to a second heat-adjusted temperature. This second heat-adjusted temperature can be increased or decreased as required. The temperature range may include heat and / or cooling. A second, smaller vessel is then A substantially mirror image of the first container so as to extend in the same direction as the first container and inside the first container. (a) removing the second smaller container from the first container; ) The side wall can be at least partially inverted while forming a second, smaller container. At least one molded recessed wall is provided to prevent at least a majority of the bottom wall from turning over. The rolling piston and the second container-shaped mold cavity set are supported by one or more wall stabilizers. The wall stabilizer is provided with two integrally joined stretch blow molded applied to at least a portion of the wall surface(s) of one or both of the enclosed containers It is.

[0037] Alternatively, the second, smaller container can be manually inverted.

[0038] The cylindrical blank may have only one open end, in which case the first dual A dual-container mold cavity set consists of at least two separate dual-container mold cavities. Each of the mold cavity halves may have an opening, ( a first container cavity recess having a sidewall (one or more) and a partially closed bottom wall. All of these mold cavity halves may have small diameter wall rigidity features and / or The mold cavity halves may further include at least a partial air gap sealing mechanism. Each of the second twisted pair has an opening, a side wall(s), and a completely closed bottom wall. A small container shaped cavity recess may be provided and all of the mold cavity halves may be of small diameter. wall stiffening feature and / or at least partial air gap sealing feature, The two container-shaped cavity recesses extend in opposite directions to each other and are inseparably joined together. is.

[0039] The tubular blank may have a first open end and a second open end, where the first The dual container shape mold cavity set may alternatively include an opening, a side(s) a first container cavity recess having a wall and a partially closed bottom wall; All mold cavity sets of the Al container shape are fitted with small diameter wall rigid features and / or at least The first dual-container mold cavity may have a partial air gap sealing mechanism. The tissette further comprises an opening, a side wall(s), and a partially enclosed bottom wall. The first dual vessel shape may have a second smaller vessel cavity recess having All of the mold cavity sets have small diameter rigid wall features and / or at least partial air gaps. The two container-shaped cavity recesses may have a gap sealing mechanism. 1 and 2, and are inseparably joined to each other.

[0040] Regardless of the shape of the cylindrical blank, the second container shape has two mold cavities. A dual container configuration having separate dual container mold cavity halves. Each of the two mold cavity halves may include at least one molded an inverted piston recess having an opening, a side wall(s), and a partially closed bottom wall; and a first container cavity recess having a first cavity recess having a second cavity recess having a second cavity recess. All halves have small diameter wall rigidity features and / or at least partial air gap closure features. Each of the two mold cavity halves may further include an opening, (one or more a second, smaller, container-shaped cavity having a side wall and a partially enclosed bottom wall. The two mold cavity halves can all have small diameter wall rigidity features and and / or at least a partial air gap sealing mechanism, The vessel-shaped cavity recesses extend in opposite directions to each other and are integrally joined together. One for thermal conditioning the blow molded first container and / or the second smaller container. or a plurality of devices, and connected to at least one subatmospheric pressure source. The nozzle may have a passageway.

[0041] The second container-shaped mold cavity set also includes two separate single-walled mold cavities. The mold cavity may also have a single-walled configuration with half cavities. a first container having an opening, a side wall(s), and a partially closed bottom wall; The axial length of the axial groove may include a small diameter wall rigidity feature and / or at least a partial Air gap closure mechanism, stretch blow molded first container and / or second smaller container one or more devices for thermal conditioning of the vessel, and at least one subatmospheric pressure source. A connecting passage may be provided.

[0042] The thermal conditioning of the first container and / or the second smaller container may be performed by Using elevated and / or reduced temperatures at any one or more locations on the smaller vessel It can be said that:

[0043] The LS of the mechanical stretching stage before the blowing stage is much larger than 1, and the RS of the cylindrical blank is max is substantially 3 or less, and the inversion of the second smaller container (one or more ) assisted by wall stabilizers and (one or more) shaped inverted pistons; The combination of two inseparably connected adjacent containers on the same side An inseparable double-walled container having a structure in which the two walls extend in the opposite directions and have an air gap between the containers, The air gap thus formed can be formed as a single unit suitable for mass production. may be partially enclosed or may be an open air gap.

[0044] Additional manufacturing steps can be added at any time in the sequence, including: This includes, but is not limited to: Uses wall stabilizer(s) and molded inverted piston(s) tensilely extending the sidewall length of the inverted second smaller container using the Any one or more of the containers and / or tubular blanks that are inseparably joined together The removal of a part of a number by any method for any reason. - Any partially closed bottom wall can be converted to a completely closed bottom wall by any method. This allows for the formation of a completely closed air gap. - Any part or wall section of any integrally joined container may be removed for any reason. The air gap can then be further inverted by any method, thereby forming a partially or completely closed air gap. A gap can be formed - Constructing a container that is inseparably joined to any one of the containers by any method for any reason By adding one or more additional parts of any shape or form to create a part. Partially or completely closed air gaps can be formed For any reason, including insulation improvements, and / or part of the user interactive configuration As a part of the composition, one or more additional materials of any form, property or nature may be added by any method. Adding it inside the air gap Ensure that the inverted second smaller container fully assumes its final design shape / form Apply additional shaping / forming techniques to Printing by any method on any surface of any inseparably joined container thing.

[0045] The thermally conditioned cylindrical blank is stretched into a first set of dual container shaped mold cavities. The cylindrical blank is stretched by mechanical and / or gas pressure devices to conform to the Therefore, at least one or more locations of the cylindrical blank are It must be sufficiently mechanically constrained to allow mechanical stretching, and , The blank must be tightly sealed so that gas pressure can be applied to the inside of the blank. It must be.

[0046] All cylindrical blank open ends may be equipped with a mechanical clamping mechanism, and at least one cylindrical The open end of the blank may have a clamping mechanism. At least one open end is substantially rounded because this facilitates mechanical attachment and sealing. This is because it provides the most reliable and efficient form of mounting for both the Unlike the open ends, the peripheral shape of the cylindrical blank may be geometrically and / or non-linearly Any combination of geometric shapes or final blow moldings as intended by design. Any relative change in circumference or circumferences due to the expansion of the cylindrical blank due to the shape of the container. It is possible.

[0047] A cylindrical blank is stretch-blow molded into a first set of cavities of a dual container configuration. When blowing, the larger the blow ratio, the more uniform the container wall thickness immediately after blowing can be. As will be apparent to those skilled in the art, it may be difficult to produce a stretch-blow molded container body. A substantially uniform blow molding is typically achieved in a substantially central region of the tubular blank. Since the thickness of the vessel wall is generally uniform in this zone, it is easy to achieve a fairly uniform vessel wall thickness in this zone. However, in the end zones of the cylindrical blank, which typically form the opening and bottom wall, When the ratio becomes large, in other words, the size of the initial cylindrical blank becomes smaller than the final container size. The smaller the wall thickness, the more difficult it is to achieve a substantially uniform wall thickness in the matching region of the container. Therefore, the size of the cylindrical blank is typically much smaller than the final container size. In this case, the wall areas near the container opening and bottom are thicker, while the wall areas in the middle of the container are thinner. become.

[0048] This is not a problem when manufacturing a large number of bottle items, but it is a problem for mass-produced containers. In the case of vessels, lack of wall thickness uniformity translates directly into material waste, resulting in a commercially higher unit product cost.

[0049] By ensuring that the RSmax of the cylindrical blank is substantially less than 3 by design, the law of nature, The wall thickness of the cylindrical blank is extremely thin compared to the final container that is stretch-blow molded. And, Thereby, the wall thickness of the tubular blank is further reduced using a mechanical drawing step, When the stretch blow molding stage begins, the tubular blank is stretched as uniformly as possible outwards. To extend.

[0050] As a result of the tubular blank design, processing equipment and manufacturing steps taught herein, Stretch blow molding of inseparable double-wall containers with extremely thin and highly uniform wall thicknesses that are practically feasible This makes it possible to form one-piece, inseparable, double-walled containers that are highly suitable for mass production. The purpose is to provide a stretch blow molding method and apparatus capable of producing ... By achieving a very uniform average wall thickness, preferably between 0.10 and 0.30 mm, be.

[0051] The cost and ease of recycling of thermoplastic resins are factors that make this method and apparatus attractive. The preferred thermoplastic resin used is polypropylene (PP), which is an integral double wall Any suitable thermoplastic resin may be used as well, depending on the specific market application of the container. Cut.

[0052] The thermoplastic resins used in the method and the apparatus are petroleum-based or bio-based, transparent / translucent, semi-transparent, Transparent or opaque, the inherent resin color of the thermoplastic resin, or any one or more colors suitable for the application Any combination of colors, single resin or blend of multiple resins, or any of these. Any combination of the above may be used.

[0053] The thermal adjustment to the first thermal adjustment temperature and the second thermal adjustment temperature is For example, cylindrical blanks and / or integral dual containers in the form of integral double-walled containers It is formed away from any relevant step in the synthesis sequence and can be heated to a thermal regulation temperature. If it is necessary to increase the temperature, For example, a cylindrical blank and / or a one-piece integral dual container may be used to form a one-piece integral double-walled container. It is formed adjacent to or integral with any relevant step in the sequence, so that it can be cooled If the temperature must be lowered to the heat adjustment temperature, the temperature is lowered, or Any combination of these, It can be said that:

[0054] Preferably, the first thermal adjustment temperature is in the order of 80-100° C. and the second thermal adjustment temperature is in the order of In the case of heating, the order of 60 to 100°C, and / or in the case of cooling, the order of 0 to The first thermal adjustment temperature may be equal to the second thermal adjustment temperature, Or both heat conditioning chambers can have different heat conditioning temperatures.

[0055] Thermal conditioning, whether it is heating or cooling, is the process of adjusting any one or more equipment parts or subsystems. This can be applied to parts as well, for example only: The cylindrical blank is stretched to conform to the shape of the first dual container mold cavity set. Helps blow molded, one-piece, inseparable dual containers to return to essentially room temperature after mating applying cooling to one or more regions of a set of mold cavities to -Prevents fracture of thin-walled cylindrical blanks during the mechanical stretching stage and / or the gas pressure blow molding stage Application of cooling to the mechanical stretching device to offset possible heat generation in the mechanical stretching device. .

[0056] Gas pressure blow molding can begin after completion of the longitudinal mechanical stretching or after the gas pressure blow molding. Pressure blow molding can begin prior to completion of longitudinal mechanical stretching.

[0057] When containers are formed with very thin walls and a high degree of wall thickness uniformity, the structural strength of the final container is For example, they typically exhibit a large radius of curvature in the radial direction and a substantial radius in the longitudinal direction. Containers such as those having conical cup walls or straight-sided bottle walls that are generally straight The more geometrically simple the curved or cylindrical wall shape in a structure, the greater the wall stiffness typically is. This reduces the stiffness of the container.

[0058] Thermoplastic resin selection can aid wall stiffness, but typically is selected from e.g. P The relatively applicable thermoplastic resins for integral, inseparable double-walled containers such as P are known to have high rigidity. One method to increase wall stiffness without affecting manufacturing costs is to use a The introduction of additional small diameter shapes or features radially and / or longitudinally into the design of the component. .

[0059] For the second, smaller container, the extension of that container in the opposite direction to the first container is A substantially mirror image position extending from the stretch blow molding position in the same direction as the first container and into the first container. The requirement to invert the vessel into a suitable position dictates a simple large diameter wall as a prerequisite. Even in the thermally softened state, the more complex the geometric shape / form, the greater the difficulty of inversion. Taking this into consideration, such a wall shape (e.g., like the inversion of a plastic contact lens) ) because it can be easily inverted. Thus, in the second, smaller container cavity recess, Cone-shaped, cylindrical, or large diameter material curved cavity walls are preferred. The second, smaller container may exhibit a relatively low stiffness, but the second, smaller container may exhibit a relatively low stiffness. The container is an integral, double-walled inner container, whose main function is to separate liquids and solids. The purpose of the container is to hold the contents, so it is suitable for use in bags in bag-in-box containers, etc. For containers in the form of a tubular container, stiffness becomes less important.

[0060] With respect to the first container, it is typically not necessary to invert this container, which may also be used, for example, as a backfill. In comparison with containers of equivalent shape such as boxes in box-in-box containers, the container is an inseparable unit. Since the main function of the outer container of a double-walled container structure is structural strength, the first container container is given priority. The vent recess maximizes thin wall stiffness in a stretch blow molded, one-piece, inseparable, double-walled container. The means for achieving this can include complex small diameter cavity wall configurations.

[0061] An important purpose of the air gap between adjacent containers that are inseparably connected together is, e.g. Maintaining a high temperature of the contents of the container, as in the case of a coffee cup, and Provides insulation, both for keeping the contents of the container cool, as in the case of cups and containers. However, because hot and cold beverages are typically consumed relatively quickly, Typically, the air gap is a completely closed and sealed air gap that effectively acts as a thermal barrier. No gap is required.

[0062] The term "fully closed" as taught in the prior art is completely unacceptable. This assumes that the double-walled container must have two completely closed bottom walls. However, when the container is not being held by the user, the integral double-walled container typically It may be stood on a substantially flat surface or held in a shipping box or tray and may be Typically, the casing is a small area below and immediately adjacent to the base of an integral double-walled container. Since there is at least a substantially flat and completely separate surface, the entire surface of the first container is The first container thus has a partially closed bottom wall. Typically there is a small underside that has a chisel.

[0063] In its simplest form, an integral non-magnetic material is formed as a result of the methods and apparatus taught herein. Some double-walled containers form an open air gap, but in particular, integral double-walled containers For reasons of structural integrity of the whole vessel and improved thermal insulation, the vessel is at least partially closed, especially the first It is reasonable to have an air gap adjacent to the partially closed bottom wall of one of the containers. As already explained, an integral double-walled container is inverted to form a second smaller container. Bag-in-box containers, where the first container is provided as a bag and the second container is provided as a box The inverted second, smaller container is typically thin-walled and This second smaller wall stiffening mechanism has little, if any, additional wall stiffening features. When liquid / solid contents are placed in the small container "bag", the bag is free to move in the first direction. There is a risk of it moving against the container, the "box." This movement could cause structural defects. While nothing bad will happen, such relative movement can at the very least be unsettling to the user. obtain.

[0064] A first dual container shape mold cavity set includes at least one or more complex sub-cavities. a cavity wall structure having a diameter extending inwardly of the first container cavity recess wall(s); By incorporating a steep / small diameter change in the form of a second, inverted smaller vessel, Any movement of the first container relative to the first container in the The first container cavity recess wall(s) may have increased structural integrity. At least one or more of the at least one or more in the form of a steep / narrow change extending inwardly in the The complex small diameter cavity wall configuration allows any one or more of the At several places, a first container can come into contact with its inverted neighbor, a second, smaller container. Cut.

[0065] Inwardly extending abruptness in the first container cavity recess wall(s) Such one or more complex small diameter cavity wall configurations in the form of changes in the curvature of the small diameter may also be A complete, one-piece assembly is used to achieve at least a partially or completely closed air gap seal. It can be used to provide an air gap restriction in an inseparable double walled container.

[0066] During this inversion process, at least a portion of the bottom wall of the second, smaller container is not necessarily inverted. Since there is no need to rotate the second smaller container bottom wall, the cavity recess corresponding to the second smaller container bottom wall is also steep / At least one or more complex small diameter cavities in the form of a cavity recess change in curvature of the small diameter The present invention can have a T-wall configuration, which is adjacent to each other in an integral double-walled vessel structure. As a further measure to reduce movement between the integral containers, and / or air gaps This can serve as a further means of providing constraints.

[0067] Producing such advantageous wall configurations in a stretch blow molded integral double wall container Therefore, the first dual container shape mold cavity set is Radial and / or longitudinal or any in between cavity wall shape and / or configuration one or more steep / narrow changes in the angular direction of the Extends any distance inward and / or outward from the average surface of any cavity wall One or more abrupt / small changes in cavity wall shape and / or morphology ll-radius change), Continuous and / or discontinuous steepness / narrowness in any direction in shape and / or form change, If it extends inward from the first container cavity wall, then by design, the final When the two walls of the container are in an integral, structural configuration, the two walls extend in the same direction. The molded first container and its inverted second container are placed in one or more locations. The contact may be contacted by contacting, contacting by engagement, or extended to a distance where contact is not possible. The presence or absence of Any combination of these Including, but by no means limited to:

[0068] Examples of complex small diameter mold cavity wall configurations include: Logos, graphic designs, lettering or sales as part of the cavity wall Any form of promotional information, Any geometric or non-geometric shape or form as part of the cavity wall; Any abrupt changes in cavity wall height, typically ridges formed, Coplanar cavity ribs or is an arbitrary abrupt change in cavity wall height typical of a cavity passage, Any kind of convex or concave thread form as part of the cavity wall, A combination of these, or Complex geometric cavity walls in the form of abrupt / narrow diameter changes that will be readily apparent to one skilled in the art composition These include, but are by no means limited to:

[0069] Additionally, the first container may have a steep / narrow inwardly extending cavity recess wall(s). One or more user interfaces in the form of abrupt / small-radius wall change By incorporating a reactive wall configuration into the first dual vessel shape mold cavity set, The inverted matching user interactive configuration is assembled into a complete, one-piece, inseparable double-walled vessel. It can be incorporated.

[0070] Such a user interactive structure thus formed on the wall of the first container may include: - Curved or helical walls extending inwards in any shape, etc. A change in wall direction extending substantially inward at a right angle, etc. - multiple interconnecting inwardly extending walls, etc. Multiple inwardly extending adjacent walls, etc. A combination of these, or Any user-interactive inwardly extending wall configuration that will be readily apparent to one of ordinary skill in the art. may include, but is by no means limited to,

[0071] The air gap formed between the first container and the inverted second smaller container is It may also be used as an integral part of the user-interactive configuration of the final formed article. This can include: One or more ball-shaped objects and / or objects that can move within the air gap space Create interactive maze-like structures by adding any other alternative shapes you can To do, One or more optional additional interfaces inserted or floating in the air gap A drive means for inducing upward, downward, forward or rearward movement of the active component. , and part of the driving means, etc., which are operated only by the user to move the completed, integral, double-walled container. do, One or more optional additional interactive components inserted within the air gap A drive means for inducing the upward, downward, forward or backward movement of the element, the air gap direct contact of the user with one or more additional interactive components inserted into the Form part of an interactive component movement involving user interaction including As part of the drive means Any combination of these, or Any other inseparable interactive configuration that will be readily apparent to those skilled in the art These include, but are by no means limited to:

[0072] During the stretch blow molding step, a heat-conditioned tubular blank having only one open end is stretched. The mechanical pressure is applied to the first dual container shape to match the shape of the mold cavity set. The container is inflated outward by the force and / or gas pressure. The first dual container shape mold cavity set typically has: The present invention has an integral interconnected cavity recess, including, but by no means limited to: A large opening for mechanical and / or hermetic engagement to one open end of a tubular blank Recess, an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be fitted with small diameter cavities for any purpose. A first container cavity recess that may have a wall configuration - an opening zone, (one or more) side wall zones and a completely closed bottom wall zone All of these zones are matingly connected with the small diameter cavity walls for any purpose. A second, smaller container cavity recess may have the configuration The first container cavity recess and the second smaller container cavity recess are inversely oriented to each other. It extends in the vertical direction.

[0073] Alternatively, during the stretch blow molding step, a heat conditioned tubular baffle having first and second open ends is formed. The rank is stretched to match the shape of the first dual container shape mold cavity set. In this way, the material expands outward due to mechanical and / or gas pressure. For wall containers, the first dual container shape mold cavity set typically includes the following: The cavity recesses are integral and interconnected, but never Not limited to: A large opening for mechanically and / or hermetically engaging and connecting with the first open end of the tubular blank. Recess, an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be any of the zones. For this purpose, the cavity wall configuration may be small. an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; These zones are all connected to a second smaller container cavity recess having a and may have small diameter cavity wall configurations for any purpose. The first container cavity recess and the second smaller container cavity recess are in opposite directions to each other. Extending to a mating member for mechanically and / or hermetically matingly connecting to the second open end of the tubular blank; Connected large opening recess.

[0074] During the inversion step of the second smaller container, the thermally conditioned second smaller container is at least The second container shape mold cavity set has: Dual container configurations typically include integral interconnected cavity recesses that The cavity recess may be in any form, but is by no means limited to the following: To provide a mechanical and / or hermetic engagement connection to the partially closed bottom wall of the first container. Large opening recess, an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; a first container cavity recess having a matingly connected first zone and a second zone; a first container cavity recess, which may have a small diameter cavity wall configuration for any purpose; an opening zone(s) and a sidewall zone(s); , a partially enclosed bottom wall zone, all of which may be small for any purpose. a matingly connected second smaller container cavity having a cavity wall configuration of Recess, The first container cavity recess and the second smaller container cavity recess are inversely oriented to each other. Extends in the direction At least one matingly connected second, smaller container bottom wall zone that is part of the second, smaller container bottom wall zone. Molded inverted piston recesses; ·moreover, A small device capable of increasing and / or decreasing the temperature of the first container and / or the second smaller container a thermal conditioning device for at least one of the first container and / or the second smaller container; at least one passageway for interconnecting with at least one subatmospheric pressure source; It may comprise:

[0075] The second, smaller container cavity recess is smaller than its corresponding first container cavity recess. The second, smaller container cavity recess may be slightly smaller than its corresponding The second, smaller container cavity recess can be significantly smaller than the first container cavity recess. The first container cavity recess has substantially the same shape / form as its corresponding first container cavity recess. or the second smaller container cavity recess may have a corresponding first The cavity recess of the container may have a shape / form that is significantly different or completely different from that of the first container cavity recess. Cut.

[0076] Alternatively, the second container shape mold cavity set is an integral, inseparable set having: The cavity recess may be in the form of a single-walled container typically having interconnected cavity recesses. However, the cavity recess is by no means limited to the following: To provide a mechanical and / or hermetic engagement connection to the partially closed bottom wall of the first container. Large opening recess, an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be fitted with small diameter cavities for any purpose. a first container cavity recess which may have a wall configuration; ·moreover, A small device capable of increasing and / or decreasing the temperature of the first container and / or the second smaller container a thermal conditioning device for at least one of the first container and / or the second smaller container; at least one passageway for interconnecting with at least one subatmospheric pressure source; It may comprise:

[0077] The cavity halves of the second container shape mold cavity set are exact mirror image copies of each other. or the cavity halves of the second container shaped mold cavity set are alternately Different cavity shapes / forms can be used.

[0078] Typically for high speed manufacturing, it is best to use slow steps in a manufacturing sequence. The goal is to increase the number of rapid steps rather than reducing the number of steps. For each step, the overall production throughput is typically determined by the slowest step. This allows for the fastest possible manufacturing sequence cycle time, thereby In order to minimize unit manufacturing costs, it is preferable to have a method and a method for manufacturing an integral double-walled container. The apparatus includes a mold cavity set having a first and a second container shape, As will be apparent to those skilled in the art, all configurations and functions of the two container-shaped mold cavity sets are Alternatively, a mold cavity set with a single-walled configuration may be used. In addition, it is possible to produce more than two mold cavity sets of container shapes in one production sequence. It is also possible to use

[0079] To ensure optimal inversion of the second, smaller vessel, the inverted wall area and the non-inverted wall area are It is important to control wall stability in the region where the If it is desired to completely invert the second, smaller container into a perfect mirror image position, The area in which wall stability control is performed in the mold cavity set of the second container shape is the first container and a connecting region between the opening zone of the second smaller container, It is only desired to partially invert the second, smaller container into a substantially mirror image position. If not, the wall stability control is performed in the mold cavity set of the second container shape. may be required for the final integral double-walled vessel shape to be formed. Any location is fine.

[0080] Where is the wall-stabilized controlled region located in the mold cavity set for the second container shape? regardless of, First, the bottom wall of the second, smaller container remains at least substantially uninverted; First, insert at least one molded inverted piston into the opening along its longitudinal axis. 2. Press the container inverted against the bottom wall of a second, smaller container using a ton; Next, starting from the bottom end of the side wall(s), Properly everting the side wall(s) gradually toward the opening end of the wall; Finally, the reversal of the opening or any other location that should be reversed last according to the design Go and finish, It is important for the inversion process to properly invert the second, smaller container. maintain the stretch blow molded wall region or regions as physically stable as possible; That is the thing.

[0081] The formed inverted piston has a flat push surface that matches the final inverted inner wall shape. Has any shape / form required to support inversion ranging from a complete molded shape It is possible.

[0082] The preferred shape of the molded inverted piston is determined by the outer surface which determines the internal surface configuration of the article to be formed. A male mold member having a surface configuration.

[0083] The surface configuration of the male mold member may be conical, convex, concave and / or any other configuration or shapes. It may be a combination of these forms.

[0084] A suitable molded inverted piston determines the inner surface of the article being formed, and therefore the inverted piston. After this, the inner surface shape of the formed article matches the outer surface shape of the molded inverted piston. The pistons engage in a mating manner, thereby positioning the molded inverted piston within the article after formation. One or more pulling assistance means may be required to extract the device from its position. A number of such extraction assistance means are known to those skilled in the art and are typically referred to as "ejection mechanisms." can be.

[0085] A suitable ejection mechanism for extraction is compressed air and / or other forms of pressure delivered to the matching engagement area. The mechanical removal mechanism is in the form of a

[0086] Disengaging the mating outer surface configuration of the molded inverted piston from the inner surface configuration of the article being formed During the ejection process, a second smaller The aim of this is to ensure that the shape, form or stability of the container is not affected. or to provide stability to a second, smaller container during inversion while applying multiple removal mechanisms. Therefore, at least one inverted secondary container stabilization device may be used.

[0087] The molded inverted piston has a surface area that determines the internal surface configuration of the article being formed. This, combined with any residual heat conditioning remaining in the article being formed, may tend to cause heat generation. . To counteract such heat generation, one or more forms of cooling means known to those skilled in the art may be provided. The piston may be incorporated within and / or adjacent to a shaped counter-rotating piston.

[0088] The wall stability control device in the second container shape mold cavity set includes: · One-piece, inseparable dual container interior stretch-blow molded at higher than atmospheric pressure during inversion A pressure above atmospheric is applied inside the second container-shaped mold cavity set to supply the Adding · The second vessel-shaped mold cavity in one or more areas required for wall stability control Through the set, one or more outer decals are attached to the stretch blow molded integral inseparable applying subatmospheric pressure to the dual vessel wall surface; Cooling at one or more locations of the second container-shaped mold cavity set. Applying Associated mechanically stretch-blow molded integral dual inner container wall surfaces To achieve adequate wall stability, at least one of the openings of the second container-shaped mold cavity set is and forming at least one mold cavity set into the second container-shaped mold cavity set using the mold cavity set. Inserting flexible wall surface support structures and / or forming a wall at the intersection of an inverted wall and a non-inverted wall. To aid in the formation of the desired final inverted shape / form at the interposition, having at least one head shape of a shape / form; A combination of these, or Mold cavity set wall stability control for any other second container shape apparent to one skilled in the art Including, but not limited to:

[0089] Air pressures higher than atmospheric pressure can now be used to invert walls, for example to create integral handle areas. It is used to provide wall stability control for stretch blow molded bottles during Typically, the relative volumetric size of the wall inversion to the total volume of the blown bottle is small. Therefore, any internal air pressure difference resulting from wall inversion can be easily controlled. do.

[0090] However, for an integral double-walled container structure, the stretch blow molded A first container and a second smaller container which are inseparable from each other, and a second container which is inverted inward from the first container. The inner space between the two smaller containers and the final integral double-walled container extending in the same direction. The difference in part volume is large, typically a factor of 10 or more. Assuming the goal is to perform the reversal as quickly as possible, these two very different internal capacities Internal air pressure generated between compartments can be difficult to control in the best of cases.

[0091] If the rate of change of the internal air pressure during reversal can be directly controlled, this can be achieved by using a pressure regulator and / or Or it can be a fast-response pneumatic control device such as a relief valve. When the rate of change of air pressure exceeds the ability of fast response pneumatic devices to reliably control The inverter stage may comprise one or more separate pressure chambers, which The present invention relates to a combination of a stretch blow molded first container and an integral, second, smaller container. The internal volume is formed by the stretch blow molded first container itself and an integral, inseparable second container. The smaller container has an internal volume substantially larger than the internal volume of the smaller container itself. In this way, when the second, smaller container is inverted, Substantial internal volume changes in stretch blow molded integral double wall containers due to rotation The conversion causes only a small change in the overall volume of the combined internal volumes, and thus the inversion The internal air pressure changes during the process can be minimized and thus easily controlled. Any combination of air pressure control device and / or one or more pressure chambers may be used. It is possible.

[0092] Achieving internal wall surface stability for stretch blow molded integral double wall containers during inversion At least one of the openings of the second container-shaped mold cavity set is used to and forming at least one flexible surface within the second container-shaped mold cavity set. The one or more flexible surface support structures can be inserted into the port structure. The structure is made of one-piece, inseparable stretch blow molded dura in areas where wall stability is required. and a spring-loaded engaging contact with the associated interior wall surface(s) of the aluminium container. To achieve this, the one or more flexible surface support structures may be spring-loaded by any suitable method. The one or more flexible surface support structures may be inverted or is flexibly inserted at any time during or after inversion and / or Can be pulled out.

[0093] At least one flexible surface support in the second container-shaped mold cavity set. The port structure is designed to form a transition area between the inverted and non-inverted walls according to design requirements. An internal moulding may be provided to ensure this.

[0094] One or more flexible surface support structures support (one or more) of an inverted double wall vessel. The springs remain in springy, engaging contact with the inner wall surfaces and are Regardless of the method used, the inverted second, smaller container remains thermally conditioned. During this time, the molded inverted piston is further expanded in the inverted direction to partially or completely A portion of the bottom wall and / or side wall(s) of the second, smaller container is fully inverted. By this means, partial or complete inversion can be achieved. Increasing the internal volume of the second, smaller container and at the same time The wall thickness of the sidewall(s) of the casing can be reduced to accommodate any particular target volume. Regarding the container volume capacity, the total empty weight of the final one-piece, inseparable double-walled container should be further reduced. This also reduces the manufacturing cost. Stretching can be done before, during and / or after wall inversion. Wall stretching can be achieved using rolling pistons or by using separate molded pistons. Sidewall stretching can be achieved by

[0095] The at least one partially enclosed bottom wall is converted into a completely enclosed bottom wall. If you need to add a processing step, this can be done by: - additional bottom wall interference fit of any suitable material, - gluing or welding of an additional bottom wall of any suitable material, An additional bottom wall of substantially the same material or of any material having suitable molecular bonding properties Additional bottom wall covering molding, - Formation of an additional bottom wall by thermal deformation of part of the original cylindrical blank, Any combination of these, or Addition of additional bottom walls as would be apparent to one skilled in the art It can be said that it is due to.

[0096] Adding additional processing steps to at least partially or completely close the air gap If you need to, this is Additional inversion of any existing wall configuration, Any form of welding process, Any form of adhesive process, Adding any form of encapsulant, - Applying adhesive labels, A combination of these, or Any form of additional sealing technique that would be readily apparent to one of ordinary skill in the art. It can be said that it is due to.

[0097] To improve the insulating properties of the air gap and / or to reduce user interaction with the air gap If you need to add further processing steps to add the active configuration, is the current to the air gap at any point in the manufacturing sequence. Gaseous materials, Liquid materials, Solid materials, or Any combination of these This may be achieved by the addition of one or more optional insulating and / or non-insulating materials, including This includes, but is not limited to, the following:

[0098] During manufacturing, in order to form a complete, one-piece, inseparable double-walled container, The entire cylindrical blank can be completely molded into an integral, double-walled container, or Cutting out unwanted / unused portions of the tubular blank using one or more post-processing steps, and / or Any blown wall portion can be cut away. For example, the machine can cut away a cylindrical blank. The mechanical and / or hermetic clamping area shall be at least that large at any point in the manufacturing sequence. You can cut out parts.

[0099] Add one or more additional structures, elements, walls or subcomponents by any device or method. Further processing steps are required to attach the components to an integral double-walled container. By way of example only, an integral double-walled container may be At any point in time Cup base, Cup handle, -Inseparable lid, Grass vine, Promotional items of any kind; Any combination of these, or Any additional features, elements, walls, or subcomponents that would be apparent to one of ordinary skill in the art etc., may include a processing step of adding such by installation.

[0100] If the inverted second smaller container does not invert completely into the desired shape / form after inversion may further include one or more further processing steps, one or more formers of any kind, application of internal and / or external air pressure, Any combination of these, or Any shape / shape correction method or device that is apparent to one of ordinary skill in the art Utilizing one or more separate devices to improve the final inverted shape / form, including The following can be used, but are not limited to these:

[0101] The multiple processing steps to form an integral double walled container are performed in-line. as separate processing steps, adjacent processing steps, or any of these Preferably, these processing steps are in-line with each other. Each processing step and each device is performed in a single process. can be performed only once in the manufacturing sequence, in any order, or in the most efficient way. In order to achieve an overall manufacturing throughput of The steps and / or device may be performed multiple times, either sequentially or non-sequentially, as desired. If desired, any one or more of the processing steps taught herein may be performed. The steps can be combined together or separated into multiple sub-steps.

[0102] An integral, double-walled container formed as a result of the method and apparatus taught herein The main market applications include: Cups and / or lids for fast food and coffee outlets, Bottles or pots for perishable food, ·Bottles or pottles for medicines, chemicals and cosmetics; Fast food containers, Secondary packaging cups, bottles or containers for any market sector These include, but are not limited to:

[0103] In a first preferred embodiment, two inseparably connected adjacent ones of the same direction are provided. A container made of thermoplastic material and joined together with an air gap between the containers. Method for manufacturing double-walled containers having a stretch-blow molded container structure suitable for mass production A method and apparatus are disclosed that first forms a thermoplastic cylindrical blank having one open end. In this case, both the stretch-blow molded integral double-walled container and the cylindrical blank are In order to minimize the wall thickness of the cylindrical blank, RSmax of the cylindrical blank is substantially set to 3 or less. The tubular blank is allowed to cool sufficiently so that the grade hardens by dropping below its melting point. Next, the cylindrical blank is heated to a temperature within the thermal softening temperature range of the thermoplastic material but below its melting point. After the heat adjustment, the cylindrical blank is heated to a temperature that is much higher than 1. The sheet is mechanically stretched in the longitudinal direction so that RLmax is less than 3, preferably on the order of 1 or less. The cylindrical blank is blown outward by gas pressure, as shown in Fig. 1. , and the combination of gas rolling in a longitudinal and / or radial direction in a consistent and elongated manner. The present invention relates to an elongated container having a structure with a first container and a smaller second container integrally and inseparably joined thereto. A blow molded, one-piece, inseparable dual container having a first container and a second, smaller container. In order to form a dual container in which the first and second containers extend in opposite directions as an intermediate product, It is assumed that the cylindrical blank will fit the shape of the mold cavity set of the container. Further heat conditioning is then performed to heat condition a second, smaller, stretch blow molded container. Applying adjustments and, if deemed advantageous, subjecting at least a portion of the first container to a second heat treatment. The second, smaller container is then placed in the same direction as the first container and in the same position as the first container. The first container extends inside the first container and is a substantially mirror image of the second smaller container. and at least partially inverting the side wall(s) of the second, smaller container to At the same time, at least a majority of the bottom wall of the second smaller container is prevented from turning over. At least one molded inverted piston and a second dual-container A mold cavity set having a shape similar to that of the mold cavity 10 is provided with one or more wall stabilizers. The device is a molded container having two inseparably joined stretch blow molded containers. Alternatively, a second such coating may be applied to at least a portion of the wall surface. Smaller containers can also be inverted manually.

[0104] The first dual container shape mold cavity set typically includes: In one embodiment, the present invention is directed to a method for manufacturing a semiconductor device, comprising: : A large opening for mechanical and / or hermetic engagement to one open end of a tubular blank Recess, an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be any of the zones. For this purpose, the cavity wall configuration may be small. - an opening zone, (one or more) side wall zones and a completely closed bottom wall zone a second smaller container cavity recess matingly connected to said first and second zones. , may have small diameter cavity wall configurations for any purpose; The first container cavity recess and the second smaller container cavity recess are inversely oriented to each other. It extends in the vertical direction.

[0105] The second dual container mold cavity set typically has: In one embodiment, the present invention is directed to a method for manufacturing a semiconductor device, comprising: : A mechanical and / or sealing member is attached to the partially closed bottom wall of the stretch blow molded first container. A large opening recess for a proper engagement connection; an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be any of the zones. For this purpose, the cavity wall configuration may be small. an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; These zones are all connected to a second smaller container cavity recess having a and may have small diameter cavity wall configurations for any purpose. The first container cavity recess and the second smaller container cavity recess are inversely oriented to each other. Extends in the direction At least one matingly connected second, smaller container bottom wall zone that is part of the second, smaller container bottom wall zone. Molded inverted piston recesses; ·moreover, at least one thermal conditioning device for the first container and / or the second smaller container; at least one passageway for interconnecting with at least one subatmospheric pressure source; It may comprise:

[0106] A mechanical stretching step before the blow molding step where LS is significantly greater than 1 and RSmax is substantially A cylindrical blank having a wall stabilizing device (or devices) and a formed backing having a wall stabilizing device (or devices) and a wall stabilizing device (or devices). In combination with the inversion of a second, smaller vessel assisted by a rolling piston, Two inseparably joined adjacent containers extending in the direction The structure of the container with an air gap between the two walls is an inseparable double-walled container suitable for mass production. The air gap thus formed can be partially sealed. It can be a closed air gap or an open air gap.

[0107] Additional manufacturing steps can be added at any sequence point, including: Inverted using wall stabilizer(s) and molded inverted pistons a manufacturing step of extending a sidewall length of the second, smaller container; Any container and / or cylindrical blank that is inseparably joined together for any reason A manufacturing step of cutting out any one or more portions of Convert any partially closed base into a completely closed base by any method. a manufacturing step in which a completely closed air gap can be formed by For any reason, any configuration or The wall section can be further inverted in any manner to create a partially or completely enclosed air gap. A manufacturing step that allows for the formation of a gap; - For any reason, any shape or form of any container that is inseparably connected to any of the containers Partially or completely by adding one or more additional parts by any method. A manufacturing step capable of forming a closed air gap; For any reason, including insulation improvements, and / or part of the user interactive configuration As a part of the composition, one or more additional materials of any form, property or nature may be added by any method. Adding it inside the air gap Ensures that the inverted second smaller container fully assumes its designed shape / form a manufacturing step of applying an additional shaping / forming technique to Printing by any method on any surface of any of the containers that are inseparably connected to one another Manufacturing Steps These include, but are not limited to:

[0108] In a second preferred embodiment, two inseparably connected adjacent ones of the same direction are provided. A container made of thermoplastic material and joined together with an air gap between the containers. For producing a dual container having a stretch blow molded container structure suitable for mass production A method and apparatus is disclosed. First, a thermoplastic sheet having a first open end and a second open end is provided. A tubular blank is formed. The tubular blank and the integral, double wall are stretch blow molded. To minimize both wall thicknesses of the container, its RSmax is substantially 3 or less. The tubular blank is allowed to cool sufficiently to harden below its melting point. The cylindrical blank is then heated to a first heat adjustment temperature within the heat softening temperature range and below the melting point of the thermoplastic material. After heat conditioning, the cylindrical blank is rotated longitudinally at an LS significantly greater than 1. Mechanically stretched to provide an RLmax of less than 3, preferably on the order of 1 or less; The first and second containers are blown outward by gas pressure. and a stretch blow molded container having a second, smaller container structure integrally and inseparably joined thereto. To form an inseparable dual container as an intermediate product, a longitudinal mechanical stretching and a longitudinal Combination of gas rolling in the axial and / or radial directions results in a cylindrical blank that is conformal. and expediently into the shape of the first dual container shaped mold cavity set. Further heat conditioning is applied to produce a second, smaller container that is stretch blow molded. and, if deemed advantageous, at least a portion of the first container at a second thermal adjustment temperature. Then, at least one molded inverted piston and a second dual chamber are placed in the mold. A set of vessel-shaped mold cavities are provided with one or more wall stabilizers. The measuring device has a second, smaller container extending in the same direction as the first container and inside the first container. the second smaller container to be a substantially mirror image of the second smaller container; and at least partially inverting the side wall(s) of the To prevent at least a majority of the bottom wall of the second, smaller container from inverting, two The wall surface of one or both of the stretch blow molded containers which are inseparably joined together Alternatively, the second, smaller container may be manually inserted. can be inverted with

[0109] The first dual container shape mold cavity set typically includes: In one embodiment, the present invention is directed to a method for manufacturing a semiconductor device, comprising: : A large opening for mechanically and / or hermetically engaging and connecting to the first open end of the tubular blank. Recess an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be any of the zones. For this purpose, the cavity wall configuration may be small. an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; These zones are all connected to a second smaller container cavity recess having a and may have small diameter cavity wall configurations for any purpose. The first container cavity recess and the second smaller container cavity recess are inversely oriented to each other. Extends in the direction a mating member for mechanically and / or hermetically matingly connecting to the second open end of the tubular blank; A large opening recess connected to the

[0110] The second dual container mold cavity set typically has: In one embodiment, the present invention is directed to a method for manufacturing a semiconductor device, comprising: : A mechanical and / or sealing member is attached to the partially closed bottom wall of the stretch blow molded first container. A large opening recess for a proper engagement connection; an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be any of the zones. For this purpose, the cavity wall configuration may be small. an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; These zones are all connected to a second smaller container cavity recess having a and may have small diameter cavity wall configurations for any purpose. The first container cavity recess and the second smaller container cavity recess are inversely oriented to each other. Extends in the direction At least one matingly connected second, smaller container bottom wall zone that is part of the second, smaller container bottom wall zone. Molded inverted piston recesses; ·moreover, at least one thermal conditioning device for the first container and / or the second smaller container; at least one passageway for interconnecting with at least one subatmospheric pressure source; may have:

[0111] A mechanical stretching step before the blow molding step where LS is significantly greater than 1 and RSmax is substantially A cylindrical blank having a wall stabilizing device (or devices) and a formed backing having a wall stabilizing device (or devices) and a wall stabilizing device (or devices). In combination with the inversion of a second, smaller vessel assisted by a rolling piston, Two inseparably joined adjacent containers extending in the direction The structure of the container with an air gap between the two walls is an inseparable double-walled container suitable for mass production. The air gap thus formed can be partially sealed. It can be a closed air gap or an open air gap.

[0112] Additional manufacturing steps can be added at any time in the sequence, including: This includes, but is not limited to: Uses wall stabilizer(s) and molded inverted piston(s) tensilely extending the sidewall length of the inverted second smaller container using the Any one or more of the containers and / or tubular blanks that are inseparably joined together The removal of a part of a number by any method for any reason. - Any partially closed bottom wall can be converted to a completely closed bottom wall by any method. This allows for the formation of a completely closed air gap. - Any part or wall section of any integrally joined container may be removed for any reason. The air gap can then be further inverted by any method, thereby forming a partially or completely closed air gap. A gap can be formed - Constructing a container that is inseparably joined to any one of the containers by any method for any reason By adding one or more additional parts of any shape or form to create a part. Partially or completely closed air gaps can be formed For any reason, including insulation improvements, and / or part of the user interactive configuration As a part of the composition, one or more additional materials of any form, property or nature may be added by any method. Adding it inside the air gap Ensure that the inverted second smaller container fully assumes its final design shape / form Apply additional shaping / forming techniques to Printing by any method on any surface of any inseparably joined container thing.

[0113] In a third preferred embodiment, the container is two adjacent containers that are inseparably joined together. A double-walled structure having two containers extending in the same direction with an air gap between the containers. To provide a method and an apparatus suitable for mass production for manufacturing a double-walled container, the double-walled container being made of a thermoplastic material. First, a thermoplastic cylindrical block with one open end is stretch-blow molded into a single piece. The two layers of the cylindrical blank and the inseparable double-walled container are stretch-blow molded. In order to minimize the wall thickness of the cylindrical brace, its RSmax is substantially 3 or less. The ink is then allowed to cool sufficiently to harden below its melting point. The rank is determined by heat conditioning to a first heat conditioning temperature within the heat softening temperature range and below the melting point of the thermoplastic material. After thermal conditioning, the cylindrical blank is mechanically aligned longitudinally at an LS significantly greater than 1. The gas pressure is adjusted so that the stretched film is stretched such that RLmax is less than 3, and preferably is on the order of 1 or less. The first container and the integral non-woven fabric are blown outwardly. Stretch blow molded one-piece inseparable container having a second smaller container structure separably joined thereto In order to form a dual container as an intermediate product, a longitudinal mechanical stretching and a longitudinal and and / or a combination of gas rolling in the radial direction to make the cylindrical blank conformal and Extending the shape of the first dual container shaped mold cavity set. By applying heat conditioning, it is possible to advantageously form a second smaller container which is stretch blow molded. and, if so, at least a portion of the first container to a second thermal conditioning temperature. The second thermal adjustment can be a temperature range including heating and / or cooling as needed. Thereafter, a male mold member having an outer surface configuration that determines the inner surface configuration of the article to be formed is inserted into the mold. At least one molded inverted piston having a shape of a single container shape and a second molded inverted piston having a shape of a single container shape. A container-shaped mold cavity set is provided along with one or more wall stabilizers. The wall stabilization device of the second smaller container is arranged in the same direction as the first container and inside the first container. to provide a second, smaller container that is a substantial mirror image of the first container so as to extend The sidewall(s) of the second, smaller container are fitted into the mold cavity of the second container shape. The side wall can be at least partially inverted without any qualitative contact, and at the same time To prevent at least a majority of the bottom wall of the second, smaller container from inverting, two The wall surface of one or both of the stretch blow molded containers which are inseparably joined together Alternatively, the second, smaller container may be manually inserted. can be inverted with

[0114] The first dual container shape mold cavity set typically includes: In one embodiment, the present invention is directed to a method for manufacturing a semiconductor device, comprising: : A large opening for mechanical and / or hermetic engagement to one open end of a tubular blank Recess, an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be any of the zones. For this purpose, the cavity wall configuration may be small. - an opening zone, (one or more) side wall zones and a completely closed bottom wall zone a second smaller container cavity recess matingly connected to said first and second zones. , may have small diameter cavity wall configurations for any purpose; The first container cavity recess and the second smaller container cavity recess are inversely oriented to each other. It extends in the vertical direction.

[0115] A first dual container shape mold cavity set is provided with at least one or more user interfaces. The interactive wall structure extends inwardly of the first container cavity recess wall(s). By incorporating steep / small wall transitions that allow for the formation of a single, inseparable, double-walled vessel in the finished product, It is possible to incorporate user interactive configurations that inversely match the

[0116] Such a first dual container shaped mold cavity user interactive wall configuration comprises: Any form of inwardly extending curved or helical wall, A change in wall direction extending substantially inward at a right angle, etc. - multiple interconnecting inwardly extending walls, etc. Multiple inwardly extending adjacent walls, etc. A combination of these, or Any user-interactive inwardly extending wall configuration that will be readily apparent to one of ordinary skill in the art. may include, but is by no means limited to,

[0117] The air gap formed between the first container and the inverted second smaller container is It may also be used as an integral part of the user-interactive configuration of the final formed article. This can include: One or more ball-shaped objects and / or objects that can move within the air gap space Create interactive maze-like structures by adding any other alternative shapes you can To do, One or more optional additional interfaces inserted or floating in the air gap A drive means for inducing upward, downward, forward or rearward movement of the active component. , and part of the driving means, etc., which are operated only by the user to move the completed, integral, double-walled container. do, One or more optional additional interactive components inserted within the air gap A drive means for inducing the upward, downward, forward or backward movement of the element, the air gap direct contact of the user with one or more additional interactive components inserted into the Form part of an interactive component movement involving user interaction including As part of the drive means Any combination of these, or Any other inseparable interactive configuration that will be readily apparent to those skilled in the art These include, but are not limited to:

[0118] The second container-shaped mold cavity set having a single container-shaped configuration typically includes the following: It may have an integral interconnected cavity recess with the one below, Including but by no means limited to: A mechanical and / or sealing member is attached to the partially closed bottom wall of the stretch blow molded first container. a large opening recess for a proper engagement connection; an opening zone, a side wall zone or zones, and a partially closed bottom wall zone; All of these zones may be fitted with small diameter cavities for any purpose. a first container cavity recess which may have a wall configuration; · It may also include: A thermal conditioning device for at least one first container and / or a second smaller container. Thermal conditioning can be the application of heat, the application of cooling, or any combination thereof. · At least one passageway for interconnecting with at least one subatmospheric pressure source.

[0119] The second container shape mold cavity set has a single container shape configuration with a second smaller container. The container is substantially free and released from the second container-shaped mold, thereby The first of the intermediate stretch blow molded integral inseparable dual containers while avoiding the enclosure. It surrounds most of container 1.

[0120] The second, smaller container is not substantially enclosed, Inside, outside, or both inside and outside a second, smaller container Regardless of whether the second, smaller container is heated, any shape or shapes may be used to heat condition the second, smaller container. Any combination of contact and / or non-contact heating in any manner may be used. The thermal conditioning of the smaller vessel can remain effective for part or all of the inversion process. do. The second, more efficient wall stability control is achieved by using internal pressures above atmospheric pressure as a means of wall stability control. The small container is allowed to expand freely outward due to its stretchability and elasticity, thereby forming a second This can improve the ability of smaller containers to be inverted without sustaining wall damage. The use of subatmospheric pressure externally as a means of wall stability control allows for a second, more The small container is allowed to expand freely outward due to its stretchability and elasticity, thereby forming a second This can improve the ability of smaller containers to be inverted without sustaining wall damage. Or any combination of these may be used.

[0121] The preferred means of thermally conditioning the second container-shaped mold cavity set involves the application of liquid cooling. This is due to the above.

[0122] A second, smaller container of an intermediate, integral, stretch blow molded dual container is formed. The preferred means of thermal conditioning is by infrared heating.

[0123] During the test, during the wall inversion of the second, smaller container, any part of the inverted wall However, there is some chance that it can move in a random direction relative to any other part of the inverting wall. When this occurs, at least a portion of the wall exceeds the elastic limit of the material, which is thought to be the cause of wall damage. It turns out it can be.

[0124] Internal supra-atmospheric pressure and / or external sub-atmospheric pressure before and during inversion The second, smaller container is elastically forced outward by applying wall stabilization control in the form of pressure. The outer surface configuration is then free to expand and determines the inner surface configuration of the article to be formed. Reversal is achieved by a molded reversal piston (or pistons) in the shape of a male mold member having a If this is done, the inverting wall(s) of the second, smaller vessel will always be in a wall stabilizing state. and a molded inverted piston(s) in the shape of a male mold member. It is constrained to move only as specified, thus preventing it from exceeding the elastic limits of the material. This allows damage-free wall inversion to be achieved.

[0125] Shaping the shape of a male mold member having an outer surface configuration that determines the inner surface configuration of the article being formed. The reversible piston may be provided with one or more ejection means and / or one or more ejection means known to those skilled in the art. The cooling means may be provided in one or more locations.

[0126] When applying a molded inverted piston ejection means, the inverted container during ejection To provide stability, a stabilizing device on the inverted second container can be engaged.

[0127] A mechanical stretching step before the blow molding step where LS is significantly greater than 1 and RSmax is substantially A cylindrical blank having a wall stabilizing device (or devices) and a formed backing having a wall stabilizing device (or devices) and a wall stabilizing device (or devices). In combination with the inversion of a second, smaller vessel assisted by a rolling piston, Two inseparably joined adjacent containers extending in the direction The structure of the container with an air gap between the two walls is an inseparable double-walled container suitable for mass production. The air gap thus formed can be partially sealed. It can be a closed air gap or an open air gap.

[0128] Additional manufacturing steps can be added at any sequence point, including: Inverted using wall stabilizer(s) and molded inverted pistons a manufacturing step of extending a sidewall length of the second, smaller container; Any one or more of the containers and / or tubular blanks that are inseparably joined together a manufacturing step of cutting out a portion of the number by any method for any reason; - Any partially closed bottom wall can be converted to a completely closed bottom wall by any method. a manufacturing step of converting the voids in the voids, thereby forming a completely closed air gap; - Any part or wall section of any integrally joined container may be removed for any reason. The air gap can then be further inverted by any method, thereby forming a partially or completely closed air gap. A manufacturing step of forming a cap; - Constructing a container that is inseparably joined to any one of the containers by any method for any reason By adding one or more additional parts of any shape or form to create a part. A manufacturing step of forming a partially or completely closed air gap. For any reason, including insulation improvements, and / or part of the user interactive configuration As a part of the composition, one or more additional materials of any form, property or nature may be added by any method. Additional manufacturing steps within the air gap; Ensure that the inverted second smaller container fully assumes its final design shape / form a manufacturing step of applying an additional shaping / forming technique to Printing by any method on any surface of any inseparably joined container Manufacturing Steps These include, but are not limited to:

[0129] Two inseparably joined adjacent containers extending in the same direction, Formed as a single unit from a cylindrical blank with an air gap between the containers and only one open end Regarding the method and / or apparatus as part of the formation of a double-walled container with the container structure formed Although these are referred to as two inseparably connected adjacent ribs extending in the same direction, a cylinder having first and second open ends with an air gap between the containers; Method for forming double-walled containers with container structure integrally formed from a shaped blank - Patents.com and / or may be part of the device, and vice versa.

[0130] inverting at least a majority of the second, smaller container, while not inverting the first container; and Although an apparatus has been mentioned, the method and apparatus include inverting at least a majority of a first container and It is equally possible that the smaller container is not inverted.

[0131] Although the method and apparatus have been described in which the second container is smaller than the first container, the method and apparatus It is likewise possible to have a first container that is smaller than the second container.

[0132] Other aspects of the invention which should be considered in all of their novel aspects are presented by way of example only. This will become apparent from the following description given.

[0133] BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the invention will become apparent from the following description, illustrated by way of example with reference to the accompanying drawings, in which: . [Brief description of the drawings]

[0134] [Figure 1] FIG. 1 is a three-dimensional cross-sectional view of a thermoplastic resin cylindrical blank according to a first preferred embodiment of the present invention. [Diagram 2] FIG. 2 is a three-dimensional view of at least a portion of a first dual container configuration mold cavity set of the same first preferred embodiment of the present invention. [Diagram 3] FIG. 2 is a three-dimensional view of at least a portion of a second dual container configuration mold cavity set of any preferred embodiment of the present invention. [Figure 4] FIG. 2 is a three-dimensional cross-sectional view of a molded inverted piston according to any preferred embodiment of the present invention. [Diagram 5] 1A-1C are three-dimensional views of alternative interior volume configurations as part of the above atmospheric pressure interior wall stability control of any preferred embodiment of the present invention. [Figure 6] FIG. 2 is a three-dimensional view of an internal flexible surface support structure of any preferred embodiment of the present invention. [Figure 7] FIG. 2 is a three-dimensional cross-sectional view of the third stretch blow molding step of the sequence for manufacturing the integral, inseparable, double-walled container of the first preferred embodiment of the present invention. [Figure 8] FIG. 2 is a three-dimensional cross-sectional view of an inversion work station with stability control device for a stretch blow molded integral first container and a second smaller container extending in opposite directions according to any preferred embodiment of the present invention. [Figure 9] FIG. 2 is a three-dimensional cross-sectional view of the first stage of the fourth inversion step of the sequence for manufacturing a one-piece, inseparable, double-walled container of any preferred embodiment of the present invention. [Figure 10] FIG. 10 is a three-dimensional cross-sectional view of a second stage of the fourth inversion step of FIG. 9 in accordance with any preferred embodiment of the present invention. [Figure 11] FIG. 11 is a three-dimensional cross-sectional view of the third inversion stage of the fourth inversion step of FIGS. 9 and 10 in any preferred embodiment of the present invention. [Figure 12] FIG. 12 is a three-dimensional cross-sectional view of a final stage of the fourth inversion step of FIGS. 9-11 in any preferred embodiment of the present invention. [Figure 13] FIG. 2 is a three-dimensional cross-sectional view of a thermoplastic resin tubular blank according to a second preferred embodiment of the present invention. [Figure 14] FIG. 13 is a three-dimensional view of at least a portion of a first dual container configuration mold cavity arrangement of the same second preferred embodiment of the present invention. [Figure 15] 1A-1C are three-dimensional cross-sectional views of the mold cavity configurations of each alternative dual container configuration of any preferred embodiment of the present invention. [Figure 16] FIG. 13 is a three-dimensional cross-sectional view of a molded inverted piston in the shape of a male mold member having an outer surface morphology that determines the inner surface morphology of the formed article, together with the article to be formed, in accordance with a third preferred embodiment of the present invention; [Figure 17] FIG. 17 is a three-dimensional cross-sectional view of an inversion work station of a third preferred embodiment of the present invention, also including a mold cavity set for a second container shape having a single container configuration, comprising a stability control device, a thermal adjustment section for the first container and / or a second smaller container, a molded inverted piston in the shape of the male mold member of FIG. 16, an ejection means for the molded inverted piston, and a stabilization device for the inverted second container. [Figure 18] 18 is a three-dimensional cross-sectional view of the inversion work station of FIG. 17 with the article to be formed of FIG. 16 inserted and ready for inversion, also according to the third preferred embodiment of the present invention. [Figure 19] FIG. 19 is a three-dimensional cross-sectional view of the inversion work station of FIGS. 17 and 18 with the article partially inverted, also according to the third preferred embodiment of the present invention. [Figure 20] FIG. 20 is a three-dimensional cross-sectional view of the inversion work station of FIGS. 17-19, where the article being formed is completely inverted into the form of a unitary, inseparable, double-walled container, also according to the third preferred embodiment of the present invention. [Figure 21]FIG. 21 is a three-dimensional cross-sectional view of an inversion work station according to a third preferred embodiment of the present invention, in which the article of FIG. 20 is fully inverted into the form of an integral, double-walled container, with the stabilizing device of the inverted second container engaged. [Figure 22] FIG. 22 is a three-dimensional cross-sectional view of the inversion work station of FIGS. 17-21 after the article of FIG. 20 has been fully inverted into a unitary, inseparable, double-walled container ready for removal from the inversion work station, also according to the third preferred embodiment of the present invention. [Diagram 23] FIG. 13 is a three-dimensional cross-sectional view of a first container shape mold of a dual container configuration having a user-interactive wall configuration in the form of an inwardly extending curved wall in a cavity wall recess of the first container, also according to a third preferred embodiment of the present invention. [Figure 24] FIG. 25 is a three-dimensional cross-sectional view of the same first container shape mold in the dual container form of FIG. 23, but having a user-interactive wall configuration in the form of an inwardly extending wall in the cavity wall recess of the first container, where the wall direction changes substantially at a right angle and the walls are interconnected or adjacent, also in accordance with a third preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0135] Terms such as "upper", "lower", "forward", and "rearward" used in this specification It is understood that the directions refer to those shown in the drawings and those obvious to those skilled in the art. These terms are used to indicate relative orientation and should not be construed as limiting in any other way. There is none.

[0136] Referring to FIG. 1, a closed thermoplastic resin cylindrical bra according to a first preferred embodiment of the present invention is shown. The ink is shown in a three-dimensional cross-sectional view.

[0137] In a first preferred embodiment of the invention, the closed tubular blank 1 has only one open end 2. and to minimize the wall thickness 3 of the closed cylindrical blank 1. and the wall thickness (not shown) of the integral dual container to be stretch blow molded. To minimize this, RSmax should be optimized by design to be substantially 3 or less. It is possible.

[0138] To stretch a cylindrical blank to fit a set of mold cavities with dual container shapes When the thermally conditioned cylindrical blank is stretched by mechanical pressure and / or gas pressure, In one or more locations - mechanically clamping the tubular blank sufficiently to allow the tubular blank to be stretched; and, - Ensuring that the blank is sealed sufficiently to allow pressure to be applied to the blank's interior It must be sandwiched between sex.

[0139] Typically, the open end 2 of the closed cylindrical blank 1 is substantially This allows for the most reliable and efficient mechanical and However, unlike the one open end 2, the periphery Shape 4 can be any combination of geometric and / or non-geometric shapes; and The perimeter is designed to accommodate the expansion of the cylindrical blank into the final double-walled container shape to be formed. The change may be any one or more of the following:

[0140] For a closed cylindrical blank 1, the mechanical clamping is achieved at one open end 2. The mechanical clamping can be achieved by one or more integral mechanical clamps at one opening end 2. The mold cavity arrangement may be in the form of a dual container shape. Engageably interconnect with a mechanical vice or clamp type arrangement (not shown) external to the body. Then, the rim-shaped mechanical clamping shape 5 is stretch-blow molded first It may form a partially closed bottom wall of a container (not shown).

[0141] For a closed cylindrical blank 1, the gas pressure is at least An internal cavity arrangement that matingly interconnects with an external sealing arrangement (not shown) of the cavity arrangement. A sealed clamp is also achieved at one open end 2 to obtain a substantially sealed passage 6 to the The closed clamping is typically provided at one open end 2 as part of the mechanical clamping configuration 5. Any combination of normal and / or additional integral inseparable features incorporated to aid in sealing It is possible to provide a combination of these.

[0142] The preferred thermoplastic resin for the closed cylindrical blank 1 is polypropylene (PP). However, any suitable thermoplastic resin may be used as well. systemic or biological, transparent / translucent, translucent or opaque, thermoplastic resin original color or any Any combination of one color or multiple colors, one type of resin or multiple types of resin or any combination thereof.

[0143] Referring to FIG. 2, a first dual container configuration of the same first preferred embodiment of the present invention is shown. At least a portion of the mold cavity set is shown in three-dimensional view.

[0144] In a first preferred embodiment of the present invention, a first dual container shape mold cavity set At least a portion of 7 typically has a plurality of inseparably interconnected cavity recesses. These cavity recesses include, but are by no means limited to: Not: A mechanically and / or hermetically secured member 2 (not shown) is attached to one open end 2 of the cylindrical blank 1. A large opening recess for mating connection 8, an opening zone 10 and (one or more) side wall zones 11 and a partially closed bottom wall a first container cavity recess 9 engagingly connected with a first container cavity recess 9 having a first zone 12 and a second zone 13. These zones All of the above may have small diameter cavity wall configurations for any purpose, and at a minimum, The bottom wall is closed by the above-mentioned mechanical and / or hermetic engagement connection configuration 8 of the end of the side wall 11. It can be said that An opening zone 14, a side wall zone(s) 15 and a completely closed bottom wall zone A second smaller container cavity recess 13 having a groove 16 and matingly connected thereto. All of these zones may have small diameter cavity wall configurations for any purpose. The first container cavity recess 9 and the second smaller container cavity recess 13 are mutually They extend in opposite directions and are inseparably connected together 17 .

[0145] Examples of complex small diameter mold cavity wall configurations include: Any form of logo, graphic design, lettering as part of the cavity wall marketing or promotional information, etc.18 Any geometric or non-geometric shape or form as part of the cavity wall ( (not shown), Any abrupt changes in cavity wall height, typically ridges,19 Flush cavity ribs that return with a steepness substantially equal to the original cavity wall height or any abrupt change in cavity wall height 20 typical of a cavity passage; Any kind of convex or concave thread form as part of the cavity wall (not shown) do not have), Any combination of these, or Complex geometric cavities in the form of abrupt / narrow diameter changes that will be readily apparent to one skilled in the art Wall Configuration These include, but are by no means limited to:

[0146] Referring to FIG. 3, a second dual vessel configuration of any preferred embodiment of the present invention is shown. At least a portion of the mold cavity set is shown in three-dimensional view.

[0147] In any preferred embodiment of the present invention, a second dual container shaped mold cavity separator is provided. At least a portion of the set 21 is typically an integral, interconnected The cavity recesses include, but are by no means limited to: into a partially closed bottom wall (not shown) of a stretch blow molded first container A large opening recess for a mechanical and / or hermetic engagement connection 22; an opening zone 24 and (one or more) side wall zones 25 and a partially closed bottom wall a matingly connected stretch blow molded first container cavity recess having a zone 26; Part 23. All of these zones may have small diameter cavity wall configurations for any purpose. At a minimum, the partially closed bottom wall can be secured to the ends of the side walls 25 by the above-mentioned mechanical and / or may be a sealing engagement connection mechanism 22; An opening zone 28 and (one or more) side wall zones 29, partially or completely closed and at least a portion of the bottom wall zone 30. A second smaller container cavity recess 27. All of these zones may be used for any purpose. and a cavity wall configuration having a small diameter at A first container cavity recess 23 that is stretch-blow molded and a second container cavity recess 24 that is stretch-blow molded The smaller container cavity recess 27 extends in opposite directions to each other and is integrally and inseparably connected. It has been continued for 31 years, A small portion as part of the bottom wall zone 30 of the stretch blow molded second smaller container 27 at least one matingly connected molded inverted piston recess 32; It may further comprise: A stretch-blow molded first container 23 and / or a stretch-blow molded second smaller At least one thermal conditioning device for the container 27, as shown (one or more ) so that the cavity heater insert 33 zone can be heated by any known method; and and / or the heated and unheated regions are separated so that a portion of the cavity remains unheated as desired. Formation of at least one separate heater insert 33 having an air gap 34 between the region It is. At least one subatmospheric pressure source (not shown) for interconnection therewith Also one aisle 35.

[0148] Referring to FIG. 4, a molded inverted piston according to any preferred embodiment of the present invention is shown. It is shown in a three-dimensional cross-section.

[0149] In any preferred embodiment of the present invention, the molded inverted piston 36 is stretch blown Ensuring that at least a majority of the bottom wall of the molded second smaller container does not invert. Therefore, the final inversion occurs from the flat pushing surface (not shown). necessary to support inversion over the complete molded shape that matches the bottom wall shape 37. It can have any shape / form. This preferred shaping is the final inverted bottom. It is a fully molded shape that matches the wall shape 37 and is stretch blow molded during the inversion process. The second, smaller container is then inserted into the second, smaller container, and the second, smaller container is then inserted into the second, smaller container.

[0150] The inverted piston 36 formed as shown in the figure is a wall inverted drive piston 36 formed as a wall inverted drive piston 36 Threaded portion 38 as one possible means of attachment to a moving mechanism (not shown). In one manufacturing sequence, any one shape / form or multiple different shapes can be used. Any number of molded inverted pistons 36 of any shape / form may be provided. For simplicity and efficiency, it is preferable to provide only one molded inverted piston 36. That is the thing.

[0151] The wall stability control device in the second dual vessel shape mold cavity set includes: A second dual vessel shape in one or more areas required for wall stability control Through the mold cavity set, any stretch blow molded part is inserted as shown in FIG. or one or more outer dual vessel walls connected to at least one subatmospheric pressure source; applying subatmospheric pressure through at least one passageway 35; To provide higher than atmospheric pressure inside the stretch blow molded container during inversion (see illustration (not shown), and a second set of dual-vessel mold cavities with above-atmospheric pressure applying a force; The final desired thickness at the intersection of the inverted and non-inverted walls (not shown) At least one flexible wall surface support structure to assist in the formation of the inverted shape / form. a second dual container mold cavity set for inserting the structure into a second dual container mold cavity set; A mechanical and / or hermetic engagement connection mechanism 22 of a mold cavity set 21 of a container shape At least one of the openings is used to expose an associated interior stretch blow molded container wall surface. and / or provide at least one of said shapes / forms with mechanical wall stability against achieving a square shape; Any combination of these, or Any other second dual container shaped mold cavity set wall that is apparent to one skilled in the art Stability Control Including, but not limited to:

[0152] Referring to FIG. 5, the above atmospheric pressure internal wall stability of any preferred embodiment of the present invention. Each alternative internal volume configuration as part of the control is shown in three-dimensional view.

[0153] For an integral double-walled container structure, first stretch blow molded sections extending in opposite directions are used. The container and an integral second smaller container 39 (two stretch blow molded containers The inner air volume and the stretch blow molded first container and the inverted second smaller container The final integral double-walled container 40 (two stretch blown containers) extends in the same direction. The difference between the internal volume of the molded container (the air gap between the molded container) and the internal volume of the molded container is large, typically more than 10 times. This results in a large volume difference. A requirement for high speed manufacturing is that the inversion must occur as quickly as possible. Assuming that the internal air pressure between these two very different internal volumes is the best case scenario. Even with a large amount of heat, it can be difficult to control.

[0154] If the rate of change of the internal air pressure during reversal can be directly controlled, this can be achieved by using a pressure regulator and / or Or by a high-speed response air pressure control device such as a relief valve (not shown). However, the rate of change of the internal air pressure is not as fast as that of a fast-response pneumatic device, and it is difficult to control it reliably. In the case where the force exceeds the limit, the inverter stage may be provided with one or more separate pressure chambers 41. The pressure chamber 41 is integral with the stretch blow molded first container 39. The combined internal volumes 42 (=39+41) and 43 (=44) of the second smaller container 40 are = 40 + 41) are the first container 39 and the second container 39 which are inseparable and stretch-blow molded. The individual internal volumes of both containers 39, 40 are substantially greater than the individual internal volume of the smaller container 40. In this way, the second stretch blow molded The smaller container is then divided into two parts, namely, the combined internal volume 42 and the combined internal volume 43. When the tube is inverted into the cavity, the combined internal volume change due to the inversion is smaller, and thus Therefore, the internal air pressure change can be minimized and easily controlled. and / or any combination of one or more pressure chambers 41. can be done.

[0155] Referring to FIG. 6, the internal flexible surface support of any preferred embodiment of the present invention The structure is shown in three dimensions.

[0156] In any preferred embodiment of the present invention, any stretch blow molded container during inversion may be The second dual-wall plate of FIG. 3 is used to provide inner wall surface stability for the vessel (not shown). Due to the mechanical and / or hermetic engagement connection 22 of the mold cavity set 21 of the container shape At least one large opening recess is used to define at least one internal flexible surface. Inserting the port structure 44 into the second dual container mold cavity set 21 The one or more flexible surface support structures 44 may provide wall surface stability. The relevant ( The spring may be adapted to spring into engaging contact with the inner wall surface (one or more) by any suitable method. The spring can be biased by

[0157] As shown, the internal flexible surface support structure 44 includes at least one spring. Each spring arm 45 has a molded head 46. The molded head 46 may be formed at the location where the inverted and non-inverted walls intersect. It is shaped / formed to assist in forming the desired final inverted shape / form. Additional springs can be inserted at any position in the flexible surface support structure 44 (see FIG. (not shown), which is advantageously inserted into the interhead gaps 47 between each molded head 46. The one or more internal flexible surface support structures 44 may include: At any point during the manufacturing sequence, whether before, during, or after inversion, It can be flexibly inserted and / or flexibly withdrawn.

[0158] The first step in the sequence for the manufacture of an integral double-walled container is the cylindrical blank shown in FIG. After the cylindrical blank 1 is produced, the cylindrical blank 1 is cooled to a temperature lower than its melting point. The cylindrical blank 1 is then rotated and allowed to cool sufficiently to harden. or may be formed integrally with or adjacent to a number of other sequence steps; or Alternatively, any one or more of the sequence steps may be formed separately. The formation method can be any suitable process known to those skilled in the art. , preferably by either injection molding or extrusion techniques.

[0159] The second step in the sequence for the manufacture of an integral double-walled container is to cut the cylindrical blank 1 into a The heat adjustment is performed by heat adjusting the temperature of the heat-adjusting material to a heat-adjusting temperature of 1. The heat adjustment can be performed by any heat-adjusting method known to those skilled in the art. The method may be a method, which may be combined with at least one other sequence step, or can be separate or distinct sequence steps. For example, the cylindrical blank 1 is The integral double walled container is heated to its thermoforming temperature as it is formed separately. If the blank needs to be heated, the heat adjustment can be an increase in temperature, for example, Another integral double-walled container forming sequence step is adjacent to or formed integrally with the If the material needs to be cooled down to its heat forming temperature, the heat adjustment is called cooling. Preferably, the average heat conditioning temperature of the cylindrical blank 1 is in the order of 80 to 100° C. It is.

[0160] Referring to FIG. 7, a single inseparable double-walled container of the same first preferred embodiment of the present invention is shown. The third step of the manufacturing sequence, stretch blow molding, is shown in three-dimensional cross-section.

[0161] In a first preferred embodiment of the present invention, the first step in the sequence for producing an integral double-walled container is Step 3 can be stretch blow molding 48 of the heat-conditioned tubular blank 1. As shown in FIG. 48a, the heat-conditioned cylindrical blank 1 is formed into a first dual container shape. The mold cavity set 7 is then loaded into the mold cavity set 7 by the device 49 as shown in 48b. The thermally conditioned cylindrical blank 1 is pressed against the support of a mechanical and / or sealing mechanism 50. The mechanical and / or sealing mechanism 50 is an integral part of the cylindrical blank 1 of FIG. The clamping mechanism 5 and the mechanical operation of the first dual container mold cavity set 7 of FIG. and / or a sealing engagement connection 8. Thereafter, gas pressure (not shown) is applied through a substantially sealed passage 6 to the mechanical and / or is applied to the inside of the mechanically stretched cylindrical blank 1, assisted by a sealing mechanism 50. can be.

[0162] The combination of mechanical stretching and gas rolling is used to stretch the thermally conditioned tubular blank 1 into a first duplex. The mold cavity set 7 of the container shape is matched to the shape of the mold cavity, thereby stretch blow molding The structure has a first container 52 and a second smaller container 53 inseparably joined together. A stretch blow molded, integral, dual container 51 having a first container 52 and a second container 53. The first and second smaller containers 53 form a dual container 51 extending in opposite directions.

[0163] The mechanical elongation LS of the thermally conditioned cylindrical blank 1 in the longitudinal direction exceeds 1, When combined with a blow molded RS at any position along the axis of the cylinder, RLma x should not be much more than 3, and is preferably substantially equal to or less than 1.

[0164] Gas pressure blow molding can begin after mechanical stretching is complete, or gas pressure blow molding can begin after mechanical stretching is complete. The shaping can begin before the mechanical stretching is completed. Thermal conditioning is performed on the first dual container shape. The first dual container shape may be formed separately from the mold cavity set 7 and / or Alternatively, the mold cavity set 7 may be formed as an integral part (not shown) of the mold cavity set 7.

[0165] Thermal conditioning, whether heating or cooling, may involve any one or more equipment parts or subparts. can be applied to any number of sports, and by way of example only: The cylindrical blank 1 matches the shape of the first dual container mold cavity set 7. When taken in an elongated manner as shown in FIG. 1, the blow molded one-piece inseparable dual container 51 is substantially cooling one or more areas of the mold cavity set 7 to assist in efficiently bringing the mold cavity set 7 back to room temperature; Applying During the mechanical stretching step 48b and / or the gas pressure blow molding step 48c, a thin-walled tubular braid is formed. In order to offset the heat generated by the mechanical stretching device 49, which may cause the destruction of the ink 1, Applying cooling to the device 49 (not shown) is possible.

[0166] Referring to FIG. 8, the reverse extending stretch blown mold of any preferred embodiment of the present invention is A stability control device for a molded, integral first container and a second, smaller container is provided. The inversion work station is shown in a three-dimensional cross-sectional view.

[0167] In any preferred embodiment of the present invention, the inversion work station 54 comprises: May include one or more of: A second dual container shaped mold cavity set 21 (substantially half of the set shown) ), At least one separate heater insert 33, shown as a stretch blow molded at least one heating technique for the first container and / or the second smaller container; At least one subatmospheric pressure source (not shown) interconnected to the at least one subatmospheric pressure source (not shown) 1 aisle 35, at least one molded inverted piston 36; Relatively small relative to the longitudinal axis of the second dual container mold cavity set 21 a method 55 for moving at least one molded counter-rotating piston 36; At least one internal flexible surface support structure 4. This can be mechanically and / or The inner flexible surface support structure is connected to the large opening recess for a sealing engagement connection 22. The structure 44 can be smoothly and freely moved from the interior of the second dual container mold cavity set 21. A spring tension plate 56 for allowing the spring tension plate 56 to be pulled out and / or passed through the inside of the The resulting spring is shown in a compressed state. A spring tension plate 56 is attached to at least one of the internal flexible surface support structures 44. 57, a method of moving the two pieces relatively in the longitudinal direction; Mounting and movement support for at least one internal flexible surface support structure 44 58, for structure Relative to the longitudinal axis of the second dual container mold cavity set 21 A method 59 for moving the structure 58 for mounting and moving support of the At least one integral pressure chamber 60, and At least one pneumatic control device (not shown).

[0168] Referring now to FIG. 9, a method for manufacturing an integral, double-walled container according to any preferred embodiment of the present invention is shown. The first of the fourth inversion step of the construction sequence is shown in a three-dimensional cross-section.

[0169] In any preferred embodiment of the present invention, the inversion step is performed by inversion workstation 54. The second dual container mold cavity set 21 is formed with two opposing mold cavities 22 extending in opposite directions. The structure of the elongated container 52 and the second smaller container 53 inseparably joined together is Begin placing the blow molded one-piece inseparable dual container 51. The integral dual container 51 may be any preferred embodiment of the present invention. Cut.

[0170] At least one of the stretch blow molded integral dual containers 51 to be inverted or The plurality of portions need to be thermally conditioned to a second thermal conditioning temperature. Thermal conditioning can be by any method. and before being placed in the inversion work station 54 and / or during the inversion process. This can be done after the work station 54 is placed inside the inverted work station. The station 54 may include at least one heater insert 33 .

[0171] The second thermal adjustment temperature can be the same or different from the first thermal adjustment temperature.

[0172] A stretch blow molded, one-piece, inseparable dual container 51 is placed inside an inversion work station 54. After being placed in the second dual-container shaped metal, a structure 58 for mounting and moving support is attached to the second dual-container shaped metal. The mold cavity set 21 can be moved longitudinally toward the mold cavity set 21, thereby forming a stretch block. - At least one internal flexible tube is provided inside the molded integral dual container 51. The surface support structure 44 can be moved. At least one internal flexible surface The insertion of the support structure 44 into the interior of the at least one interior flexible surface support This can be assisted by a spring tension plate 56 which spring-compresses the seat structure 44, thereby Stretch blow through the large opening recess for mechanical and / or sealing engagement connection 22. The molded, one-piece, inseparable dual container 51 can move smoothly and freely inside. .

[0173] Referring to FIG. 10, the fourth inversion switch of FIG. 9 in any preferred embodiment of the present invention is The second stage of the process is shown in a 3D cross-section.

[0174] In any preferred embodiment of the present invention, at least one internal flexible surface support The port structure 44 is properly fitted inside the stretch blow molded integral dual container 51. Once positioned, the spring tension plate 56 forms an integral, stretch blow molded dual container. It can be pulled out backwards based on 51, which allows the internal flexible surface support The seat structure 44 is spring-loaded 61 outward to provide an extension block that may require inversion support. - One or more associated inner surfaces of the molded integral dual container 51 The surface can be matingly connected / contacted.

[0175] At least one pressure source (not shown) is provided to the associated stretch blow molding unit. A pressure 62 above atmospheric pressure is applied to the interior of the inseparable dual vessel 51 and the pressure chamber 60. It is possible.

[0176] At least one pressure source (not shown) is attached to a stretch blow molded, one-piece, integral At one or more optional relevant locations (not shown) external to the dual vessel 51: Subatmospheric pressure may be applied.

[0177] Referring to FIG. 11, the first embodiment of FIG. 9 and FIG. 10 in any preferred embodiment of the present invention will be described. The third inversion stage of the four inversion steps is shown in a three-dimensional cross-sectional view.

[0178] In any preferred embodiment of the present invention, a stretch blow molded integral dual Any one or more associated zones of the vessel 51 are thermally conditioned to a second thermal conditioning temperature. and if any one or more wall stability control techniques are applied, the stretch blow molded At least one molded inversion member is provided to initiate the inversion of the second smaller container 53. The piston 36 is longitudinally aligned with respect to the stretch blow molded integral dual container 51. It can be moved in direction 63.

[0179] To ensure optimal inversion of the stretch blow molded second smaller container 53, It is important to control the wall stability in the region where the rolling wall section and the non-inverting wall section are engaged with each other. The key is: A second smaller stretch blow molded container 53 is completely inverted to a perfect mirror image position If desired, a wall stabilizer may be provided in the second dual container mold cavity set 21. The areas where constant control is performed are the opening zone 64 of the first stretch blow molded container 52 and the second the connecting area between the opening zone 64 of the two smaller containers 53, A second smaller container 53 that is stretch blow molded is only partially in a substantially mirror image position. If inversion is desired, a second dual container shaped mold cavity set 21 is inserted. The area where wall stability control is performed in the final integral double-walled vessel shape is The location may be anywhere that is considered necessary for the design.

[0180] Initially, at least a majority of the bottom wall 65 remains uninverted and the opening 64 At least one shaped inverted piston is adapted to move in a longitudinal direction 63 toward the 36 to push invertedly against the bottom wall 65 of the second smaller container 53; Then, starting from the bottom end of the side wall(s), The side wall(s) 66 are gradually adjusted toward the open end 64 of the side wall 67. Inverted, Finally, the reversal of the opening 64 or any other location that should be the last to be reversed by design. The process ends with a rotation. The inversion step ensures that the stretch blow molded second smaller container 53 is properly inverted. In order to achieve this, a second dual-container mold kit is provided in which the wall stability control area is located. At any location within the cavity set 21, the associated stretch blow molded (one or more ) It is important to keep the wall area as physically stable as possible.

[0181] At least one internal flexible surface support structure 44 may be, by way of example only, an aperture At the intersection of the inverted wall and the non-inverted wall, as shown as the inner zone 64, To aid in the formation of the desired final inverted shape / form, at least one of the shapes / forms described above may be It may have one head shape.

[0182] At any point in the sequence, the springs will deflect outwards as needed. 61, any one of the stretch blow molded integral inseparable dual containers 51 and / or a plurality of associated inner surfaces of the first and second electrodes. at least one internal flexible surface support structure 44; - pressure above atmospheric 62, which may be applied or released at any time in the sequence; Subatmospheric pressure (not shown) that may be applied or released at any time in the sequence or Any combination of these Any one or more wall stability control techniques may be at any particular time in the inversion sequence, including The present invention can be, but is not limited to, operable at various points.

[0183] Also, without applying any wall stability control method, e.g. only when the inversion is performed manually. Inversion can also be performed.

[0184] Referring to FIG. 12, the fourth embodiment of FIGS. 9 to 11 in any preferred embodiment of the present invention The final stage of the inversion step is shown in a 3D cross-sectional view.

[0185] In any preferred embodiment of the present invention, at least one molded inverted piston 3 When 6 reaches its final design position in the longitudinal direction 63, the inversion is completed. at this point Extending 58 at least one internal flexible surface support structure 44 and spring The tension plate 56 springs the inner flexible surface support structure 44 again. The tension plate 56 can be moved, or Prior to this withdrawal, at least one internal flexible surface support structure 44 The inverted walls remain engaged so that they can extend expansively (as shown). At least one shaped counter-rotating piston 36 continues to move further in the longitudinal direction 63. It can continue.

[0186] To complete the fourth reversal step, -Can release any pressure above atmospheric pressure at any time 62 Any subatmospheric pressure source (not shown) can be released at any time. tree, At least one molded reversible piston 36 is placed in its home position (not shown) ) and back in.

[0187] The mechanical stretching step before the blowing step, where LS is significantly greater than 1, and RSmax is essentially 3 or less than three cylindrical blanks and at least one dual-container shaped mold cavity. As a result of the combination of the set and the molded piston(s), A first container 69 and a second smaller container 70 inseparably joined thereto at least in a substantially inverted manner. The structure of the small container 71, in which the first container 69 and the inverted second smaller container 71 are The two containers are open or at least partially sealed by extending in the same direction. The structure forms an air gap 72, and the structure is inseparable as a single unit suitable for mass production. A double-walled container 68 can be formed.

[0188] Any one or more of the containers and / or tubular blanks that are inseparably joined together cutting off a portion of the number by any method for any reason; - Any partially closed bottom wall can be converted to a completely closed bottom wall by any method. Transforming the material into a completely closed air gap. , - Any part or wall section of any integrally joined container may be removed for any reason. The air gap can then be further inverted by any method, thereby forming a partially or completely closed air gap. A step of forming a gap; - Constructing a container that is inseparably joined to any one of the containers by any method for any reason By adding one or more additional parts of any shape or form to create a part. forming a partially or completely closed air gap; For any reason, including insulation improvements, and / or part of the user interactive configuration As a part of the composition, one or more additional materials of any form, property or nature may be added by any method. adding within the air gap; Ensure that the inverted second smaller container fully assumes its final design shape / form applying additional shaping / forming techniques to Printing by any method on any surface of any inseparably joined container Steps Additional manufacturing steps, including However, the present invention is not limited to the above.

[0189] In situations where high volume production speed is not required, a second smaller container is manually inverted instead. It is possible.

[0190] Referring to FIG. 13, an open thermoplastic resin tube in a second preferred embodiment of the present invention is shown. The shaped blank is shown in a three-dimensional cross-sectional view.

[0191] In a second preferred embodiment of the present invention, an open tubular blank 73 has a first open end 74 and a second open end 75, minimizing a wall thickness 76 of the open tubular blank 73; Furthermore, the wall thickness of the integral double-walled container (not shown) to be stretch-blow molded is minimized. In order to minimize this, the RSmax of the opened cylindrical blank 73 is substantially 3 or less. The design can be optimized so that

[0192] Thermally conditioned cylindrical blanks are stretch-fitted into a dual-container mold cavity set In order to achieve this, the cylindrical blank is stretched by mechanical and / or gas pressure. In one or more locations, Mechanically clamping the tubular blank sufficiently to allow it to be stretched death, - Enough space for applying pressure to the inside of the cylindrical blank The parts must be hermetically sealed.

[0193] The open ends 74 and 75 of the open cylindrical blank 73 are fully rounded (as shown). However, unlike the open ends 74 and 75, the blank is typically of a cylindrical shape. The perimeter shape 77 may be any combination of geometric and / or non-geometric shapes or The expansion of the cylindrical blank due to the final double-walled container shape to be formed as intended by the design The change in the circumference may be any relative change in one or more of the circumferences relative to the circumference of the object.

[0194] For an open cylindrical blank 73, mechanical clamping is performed at both ends 74 and 75. The mechanical clamping may consist of one or more integral non-contact clamps at one and / or both open ends. The mold can be in the form of a separable mechanical clamping feature 78, which may be used in a dual container mold kit. Engageable with a mechanical vice or clamp type arrangement (not shown) outside the cavity arrangement. No clamping feature 79 is provided at one and / or both open ends. is also possible.

[0195] For the open cylindrical blank 73, the gas pressure is at least substantially sealed off to the inside. A sealing clamp may also be provided at one and / or both open ends to obtain a passage 6, This passage 6 is external to a dual container mold cavity arrangement (not shown). The sealing arrangement is typically a type of mechanical clamping. The usual and / or additional integral features are incorporated as part of the sealing Any combination of the above may be provided.

[0196] The preferred thermoplastic resin for the open cylindrical blank 73 is polypropylene (PP). However, any suitable thermoplastic resin may be used as well. systemic or biological, transparent / translucent, translucent or opaque, thermoplastic resin original color or any Any combination of one color or multiple colors, one type of resin or multiple types of resin or any combination thereof.

[0197] Referring to FIG. 14, the first dual-capacity At least a portion of the vessel-shaped mold cavity arrangement is shown in three-dimensional view.

[0198] In a second preferred embodiment of the present invention, a first dual container mold cavity arrangement At least a portion of 80 is typically A first dual container configuration having a plurality of inseparably interconnected cavity recesses. At least a portion of the mold cavity set 81, but not limited to this. This includes, but is by no means limited to: A mechanical and / or mechanical device connectable to at least one open end of the open cylindrical blank 73. 82 is a large opening recess for a sealing engagement connection, an opening zone 84 and (one or more) side wall zones 85 and a partially closed bottom wall A first container cavity recess 83 having a matingly connected zone 86. These zones All of the above may have small diameter cavity wall configurations for any purpose. an opening zone 88 and (one or more) side wall zones 89 and a partially closed bottom wall A second smaller container cavity recess 87 having a zone 90 matingly connected thereto. All of these zones may have small diameter cavity wall configurations for any purpose. The first container cavity recess 83 and the second smaller container cavity recess 87 are 91 Arrangements for assisting the mechanical stretching of the opened tubular blank 73, comprising two The blank is a thermally conditioned tubular blank having an open end and is mechanically stretched in the longitudinal direction 94 as shown. At least one open end 93 of the open tubular blank 73 and any The arrangement is in the form of an arrangement 92 that can be sealed and / or mechanically engaged by known techniques. body.

[0199] Each processing step to form an integral, double-walled container is an in-line processing step. as adjacent processing steps, or as separate processing steps, or Preferably, these processing steps are performed in-line. and / or adjacent to each other.

[0200] Each process step and equipment device taught may only be used once in a manufacturing sequence. Any one or more process steps and / or apparatus may be performed in any order. The device can be continuously cycled as needed to maximize overall manufacturing throughput. One or more of the treatment steps taught may be performed multiple times or non-sequentially. The steps can be combined together as needed or separated into sub-steps. can be done.

[0201] Two inseparably joined adjacent containers extending in the same direction The container is made of a cylindrical blank having an air gap between the containers and only one open end. 11. A part of the formation of a stretch blow molded double wall container, comprising a container structure formed by When referring to a method and / or apparatus as a adjacent containers inseparably joined together with an air gap between the containers. The container is unitarily formed from a cylindrical blank having a first open end and a second open end. A method and / or apparatus for forming a stretch blow molded double wall container comprising the structure It can also be part of the setup and vice versa.

[0202] Method and apparatus for inverting at least a majority of a second, smaller container while not inverting a first container When referring to a dispensing arrangement, the method and apparatus may include inverting at least a majority of the first container. It is also possible that the second, smaller container is not inverted.

[0203] When referring to methods and apparatus where the container inversion is the result of a mechanical device, The apparatus may also have one or more manual container inversion steps.

[0204] Referring to FIG. 15, a number of alternative second The mold cavity configuration for the dual vessel shape is shown in a three-dimensional view.

[0205] In any preferred embodiment of the present invention, the second, smaller container cavity recess is The first container cavity recess may be slightly smaller than the corresponding first container cavity recess, or may be a second container cavity recess. The smaller container cavity recess is significantly smaller than its corresponding first container cavity recess. (not shown).

[0206] The second, smaller container cavity recess is substantially the same as its corresponding first container cavity recess. The first cavity 92 may have substantially the same shape / form 95 or may have a second, smaller container cavity. The recesses have a shape that is significantly different or completely different from the corresponding first container cavity recesses. The mold cavity of the second container shape may have a shape / configuration 96. The bitty set halves can be exact mirror images of each other or can be shaped to fit a second container shape. The mold cavity halves of a mold cavity set have different cavity shapes / configurations. It is possible to have a (not shown).

[0207] An integral, double-walled container formed as a result of the method and apparatus taught herein The main market applications include: As shown in the dual container mold cavity configuration in each figure by way of example only, Cups for fast food and coffee shops, By way of example only, a dual-vessel mold cavity configuration 97 is shown. dishes or lids for food and coffee shops; By way of example only, dual vessel mold cavity configurations 98 and 99 are shown. , bottles or pottles for perishable food, medicines, chemicals and cosmetics, By way of example only, a dual container mold cavity configuration 100 is shown. Containers for fast food, By way of example only, dual vessel geometry mold cavity configurations 97, 98, 99 and 100 Secondary packaging for any market sector, such as cups, glasses, bottles, plates, Lid or container These include, but are not limited to:

[0208] FIG. 16 is a third preferred embodiment of the present invention for determining the internal surface morphology of the formed article. A molded inverted piston having a shape of a male mold member having an outer surface configuration is inserted into the molded object. This is a three-dimensional diagram showing the product.

[0209] The inverted piston 101 molded in the shape of the male mold member of the third preferred embodiment is formed The article 104 may have an outer surface configuration 102 that determines an inner surface configuration 103 of the article 104 being processed. (In this figure, the article 104 being formed is inseparably connected to the first container 105. The intermediate product of the second container 106 structure is a stretch blow molded integral inseparable dual 1, the first container 105 and the second container 106 are shown in the form of a container. (The two extend in opposite directions and are formed as a single unit.)

[0210] The inverted piston 101 molded in the shape of a male mold member may comprise: can: Optional one or more extraction means 107 (shown here in the form of compressed air passages) ), One or more heat regulation means 108, either inside and / or outside (in the figure, (shown in the form of cooling passages).

[0211] The surface form 102 of the inverted piston 101 formed in the shape of the male mold member is conical (as shown in the figure). (shown), convex (not shown), concave (not shown) and / or other It may be in any form or combination of these forms.

[0212] After the second container 106 is inverted, the molded inverted piston 101 in the shape of the male mold member is inserted. determines the inner surface 103 of the article 104 being formed, The piston 101 at least substantially matches the shape of the male mold member. (not shown) thereby forming a molded inversion of the shape of the male mold member. To withdraw the piston 101 from its position within the formed article, one or more pulls are required. A number of such extraction assistance means are known to those skilled in the art. Typically, this is referred to as an "ejection mechanism."

[0213] The preferred extraction mechanism during extraction is compressed air (as shown in the figure) supplied to the matching engagement area. via an air passageway) and / or other form of mechanical removal mechanism (not shown).

[0214] The inverted piston 101 formed in the shape of the male mold member is adapted to contact the inner surface of the formed article (FIG. (not shown) to determine any residual heat conditioning remaining in the formed article. In combination, there may be a tendency for heat generation. To counteract such heat generation, one or more of the following methods known to those skilled in the art may be used: One or more forms of cooling means 108 (in the figure in the form of internal cooling passages 108) are provided on the The molded inverted piston 101 may be incorporated into the interior and / or exterior of the molded inverted piston 101. can be done.

[0215] FIG. 17 shows a mold cavity set for a second container shape having a single container configuration and a stable control The device includes a thermal control portion of a second, smaller container, and a molded inverted piston in the shape of a male mold member. a molded inverted piston ejection means; and an inverted second container stabilizing device. FIG. 13 is a three-dimensional view of an inversion work station according to a third preferred embodiment of the present invention, .

[0216] In the same third preferred embodiment of the present invention, the inversion work station 109 comprises: a second container shape mold cavity set having a single container configuration; A stability control device 111 (here in the form of an above-atmospheric internal air pressure system) and, A thermal conditioning unit 112 (here in the form of an infrared heating system) for the second, smaller container ) and The molded inverted piston may be provided with a removal means 107 and / or a heat adjustment means 108. an inverted piston 101 molded in the shape of a male mold member; A stabilizing device 113 for the inverted second container (in the figure, in the form of a removable stiffening mechanism) There is) It can be provided with:

[0217] A second container-shaped mold cavity set having a single-walled configuration is provided for heating and and / or access to cooling heat adjustment section and / or subatmospheric pressure wall stabilizer (not shown), etc. A path 114 may also be provided.

[0218] FIG. 18 is a third preferred embodiment of the present invention, in which the article formed in FIG. 16 is inserted. FIG. 18 is a three-dimensional view of the inversion work station of FIG. 17, ready for inversion.

[0219] In the same third preferred embodiment of the present invention, the article 104 being formed is fed to an inversion work station. The motor is inserted into motor 109 and is ready to be inverted. After it is inserted, At least a large portion of the side wall(s) 105 of the first container of the article 104 to be formed The part is enclosed 115 in a second container-shaped mold cavity set 110; A small portion of the sidewall(s) 106 of the second, smaller container of the article 104 being formed At least a majority of the second container shape is not enclosed by the mold cavity set 110 116 .

[0220] At least a majority of the second smaller container 106 is molded into a mold cavity having a shape of the second container. By not being surrounded by the net 110, Either inside or outside the second smaller container 106 (as shown), or thermally conditions the second, smaller container 106, whether it is both internal and external. Contact and / or non-contact heating in any form or combination of forms for 112 can also be used. The thermal conditioning 112 of this second smaller vessel may be effective during part or all of the inversion process. The results can be sustained. Use of internal above-atmospheric pressure and / or external below-atmospheric pressure as a wall stability control method By using full pressure (not shown), The thermally conditioned second smaller container 106 is stretchable and elastically expandable outwardly. This reduces the ability of the second, smaller container 106 to invert without sustaining wall damage. can be improved.

[0221] FIG. 19 also shows a third preferred embodiment of the present invention in which the article formed is partially inverted. FIG. 19 is a three-dimensional view of the inversion work station of FIGS. 17 and 18.

[0222] In the same third preferred embodiment of the present invention, at least one of the walls of the second smaller container 106 At least one male mold part is stretchable and elastic and can expand outwardly. The inverted piston 101 having the shape of the material is inserted into the second single-walled mold cavity 110. 117, the inversion is ready to be performed by displacing the inversion plate 117 in the longitudinal direction 118 of the At least a partial bottom wall 119 of the second smaller container 106 is provided with at least one Engage with the inverted piston 101 formed in the shape of a molded part, The at least one male mold member is formed into a shape of a second inverted piston 101. A second, smaller container is formed by displacing the first container in the longitudinal direction 118 of the single-container mold cavity 110. At least a partial bottom wall 119 of the first container 106 is displaced toward the first container 105. , At least one side wall of the article 104 being formed is at least partially shaped to conform to the bottom wall 119. 120 As the position progresses, the product gradually reverses. The inner surface shape of the piston 101 is gradually changed to the outer surface shape of the inverted piston 101 formed in the shape of the male mold member. 120 This results in a formed article 104 being formed.

[0223] Thermal conditioning and internal and / or external pressure profiles prior to and during inversion 120 and applying wall stability control (not shown) to the second, smaller vessel 10 6 is stretchable and elastic and can expand outwardly, and the article 101 formed forming a shape of at least one male mold member having an outer surface configuration that determines an inner surface configuration of the When inversion is performed by a reversing piston, the second smaller container 106 (one The reversing wall 120 (or walls) is always in contact with the wall stability control and the (one or more) of the shape of the male mold member. The pistons 101 are molded in a circular motion and are restricted to move only as specified by the pistons 101. This prevents the everting wall 120 from exceeding the elastic limit of the material. Thus, damage-free wall inversion can be achieved.

[0224] FIG. 20 is a view similar to that of FIGS. 17-1, in which the article is completely inverted, according to the third preferred embodiment of the present invention. FIG. 9 is a three-dimensional view showing the inversion work station.

[0225] In a third preferred embodiment of the present invention, the shape of at least one male mold member is The inverted piston 101 is inserted in the longitudinal direction of the second single-walled mold cavity 110. 21, thereby forming a completely inverted article 122 ( In the figure, a first container and a second container are inseparably connected to each other. a dual container, the first container and the second container extending in the same direction as each other; (It is in the form of a dual container formed as a single unit).

[0226] FIG. 21 shows a third preferred embodiment of the inversion work station of the present invention, and FIG. A three-dimensional view showing the item fully inverted and the stabilizing device of the inverted second container engaged. FIG.

[0227] In the same third preferred embodiment of the present invention, once the article is fully inverted 122, the male mould part At least a majority of the molded inverted piston 101 in the shape of the material corresponds to the formed article 123. 122 from the inside of the fully inverted article 122. When the inverted piston 101 formed in the shape of the male mold member is pulled out, one or more pulls are performed. A removal assistance means may be required.

[0228] The outer surface shape of the inverted piston 101 formed in the shape of the male mold member and the article 1 after formation Upon disengagement of at least a majority of the mating internal surface configuration of 22, the male mold member The drawing process is used as a means to support the outer surface shape of the inverted piston 101 formed in the shape of During the process, the shape, configuration or stability of the second, smaller container, which is at least mostly inverted, It is important not to affect the second smaller At least one stabilizer 113 of the container is coupled to the formed article 122 by engagement. 124 (which in this figure takes the form of mechanical removal reinforcement portion 113).

[0229] In the case of applying the extraction assistance means, the stabilizing device 113 of the inverted second smaller container may cause any part of the formed article 122 to move in any direction detrimental to the overall stability. It is possible to prevent this.

[0230] FIG. 22 shows the third preferred embodiment of the present invention, in which the article of FIG. 20 is completely inverted and taken out. FIG. 22 is a three-dimensional view of the inversion work station of FIGS. 17-21 ready for ejection.

[0231] In the same third preferred embodiment of the present invention, a molded inverted piston in the shape of a male mold member is provided. At least a majority of the first electrode 101 is withdrawn back to its starting position and an inverted second smaller electrode 102 is inserted. At least a majority of any stabilizer 113 of the container is withdrawn back to its starting position. After being inverted, the fully inverted article 122 (shown in FIG. 1 as a single inseparably joined first container and A dual container having an inseparable structure with a first container and a second container. The dual container is formed as a single unit in which the container and the container extend in the same direction. The cartridge (which is currently in the process of being removed) can be in a ready-to-remove state.

[0232] FIG. 23 is a perspective view of a third preferred embodiment of the present invention, showing an inwardly extending curved wall configuration. in a cavity wall recess of the first container. FIG. 2 is a three-dimensional view of a mold for a first container shape of the embodiment.

[0233] In the same third preferred embodiment of the present invention, the first container cavity wall recess 126 and the second A first container shape mold for a dual container configuration including a smaller container cavity recess 127. 125 is in the form of a curved wall 128 that extends inwardly into a first container cavity wall recess 126. The present invention can be provided with a user interactive configuration.

[0234] By way of example only, a formed article may have a first container and an inverted second smaller container. The resulting air gap (not shown) between the first container wall of the formed article is filled with the anti-reflection film provided in the first container wall. The curved walls that run inward and outward form an integral part of the user interactive structure. It can be used as part of One inserted into the fluid in the air gap and / or the air suspended in the air gap or any additional interactive components (not shown) above, below, in front of, or is a driving means for inducing the rearward movement, and is used to drive the completed, integral, double-walled container. Use as part of a driving means etc. by only moving the device, One or more optional additional interactive components inserted within the air gap A drive means for inducing upward, downward, forward or backward movement of an element (not shown) The user with one or more additional interactive components inserted into the app gap Interactive component operation through direct user interaction, including direct contact with the Use as part of a drive means forming part of the movement These include, but are not limited to:

[0235] FIG. 24 shows a third preferred embodiment of the present invention, in which the wall direction changes substantially at a right angle, User interactive walls in the form of inwardly extending walls, where the walls are interconnected or adjacent The same first embodiment of the dual vessel configuration of FIG. 23 has the structure in the cavity wall recess of the first vessel. FIG. 1 is a three-dimensional view of a mold for the container shape of FIG.

[0236] In the same third preferred embodiment of the present invention, the first container cavity wall recess 126 and the second A first container shape mold 1 of a dual container configuration including a smaller container cavity recess 127 25 is an inwardly extending wall where the wall direction changes substantially at a right angle or where the walls are interconnected or adjacent. A user interactive configuration in the form of a wall 129 present in the cavity wall recess of the first container. 126.

[0237] As merely one example, the formed article may have a first container and an inverted second smaller container. The resulting air gap (not shown) between the first and second electrodes is closed by an inwardly extending curved wall 129. The inverted, inwardly extending wall, e.g., substantially Any combination of generally perpendicular wall direction changes, interconnecting walls, and adjacent walls. can be used with inverted, conforming, inwardly extending walls of the formed article, etc., all of which Forming an integral part of the user interactive configuration, including: One or more ball-shaped objects and / or objects that can move within the air gap space Create interactive maze-like structures by adding any other alternative shapes you can (not shown) If necessary, any air gap may be provided. Fluid in the form of a liquid can be added.

[0238] It has a structure of two inseparably joined adjacent containers extending in the same direction. A structure in which the double-walled container is formed as a single unit with an air gap between the containers. Creating a user interactive configuration of the final formed article in the form of a double-walled container having To achieve this, the inwardly extending wall configuration may have any number or combination of shapes and configurations. The first container of the first container shape mold of the dual container form is formed by any number of combinations. It will be apparent to one skilled in the art that the ventilator may be incorporated into the ventilator wall.

[0239] Although the method and apparatus have been described in which the second container is smaller than the first container, It is equally possible for the first container to be smaller than the second container.

[0240] In the above description, reference is made to whole or components that have known equivalents. Such equivalents are hereby incorporated by reference in their entirety as if each such equivalent was individually set forth. do.

[0241] Although the present invention has been illustratively described with reference to possible embodiments thereof, the scope and spirit of the present invention are not to be construed as limiting the scope of the present invention. It is apparent that improvements and / or modifications may be made to the present invention without departing from the spirit and scope of the invention. Any one or more of the elements in any embodiment may be combined in any order. Other embodiments are possible that will be readily apparent to one of ordinary skill in the art.

Claims

[Claim 1] (a) a pair of unitary, inseparable containers formed as a single unit from a cylindrical blank of thermoplastic resin, the containers being spaced apart to define a closed air gap between the containers; A double-walled container comprising: (b) a wall of at least one of said containers having at least one user interactive component; (c) the at least one user interactive component is contained in the air gap; (d) a wall of at least one of the containers has at least one geometric configuration that forms a user-interactive maze-like structure with an air gap containment component; (e) a wall of at least one of the containers has at least one geometric configuration that, together with an air gap containment component, provides a means for driving the air gap containment component up, down, forward, or backward within the closed air gap. A double-walled container characterized in that

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