Applicator Container Forming and Filling Integration
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Solution Overview
Problem
The production of applicators for fluid or pasty media, such as markers, is hindered by high costs due to inefficient manufacturing processes, which limits economic feasibility in mass production.
Innovation Solution
A method involving the formation of a container from an extruded flexible thermoplastic tube using the blow and fill process, allowing for rapid and efficient production by applying overpressure or vacuum, and simultaneous filling and shaping within a mold, with the application element being affixed through molding while the container is still in an adaptable state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate production processes are used for container forming, filling, and application element attachment, then each process can be optimized independently, but the overall production speed is reduced and costs increase
Solution Approach 1:
The patent combines container forming, filling, and application element attachment into a single integrated mold system. The mold includes both forming cavities for the container and positioning/attachment mechanisms for the application element, allowing all operations to occur simultaneously in one production cycle, thereby dramatically increasing productivity.
Solution Approach 2:
The mold serves multiple functions: it forms the container shape, fills it with medium, positions the application element, and attaches the element to the container. This multi-functional approach eliminates the need for separate production lines and handling steps, reducing overall process complexity despite the integrated design.
2Ease of manufacture
If the container is formed and filled separately before attachment of the application element, then each step can be quality-controlled independently, but the production rhythm is extended and costs rise
Solution Approach 1:
The application element is pre-positioned within the mold cavity before the container forming and filling operations commence. This preliminary positioning ensures that when the container is formed and filled, the application element is already in the correct location, eliminating subsequent alignment and attachment time, thus reducing production cycle time while maintaining manufacturing quality.
3Adaptability or versatility
If multiple production steps are performed sequentially outside the mold, then each step can be optimized for quality, but the production rhythm slows down and adaptability is reduced
Solution Approach 1:
The mold system dynamically adapts to accommodate different container shapes and application element types through interchangeable inserts and adjustable positioning mechanisms. This dynamic adaptability allows the same mold to produce various applicator configurations without requiring separate production lines, maintaining high production speed while enabling versatility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly accelerates the production speed and reduces costs, making large-scale production of applicators more economically viable by integrating shaping, filling, and affixing processes within a single mold operation.
Implementation Method 1
forming the shape of the container, can be carried out by applying an overpressure and/or a vacuum
Implementation Method 2
forming the shape of the container, can be carried out by applying an overpressure and/or a vacuum
Implementation Method 3
The application element is affixed by a closing movement of movable mold parts. The malleable plastic material of the container is correspondingly molded, preferably to simultaneously form a closure to the container.
Implementation Method 4
an application element, which is attached to the container in a usage position such that the application element provides the medium for application outside of the container through capillary action
Data Source
AI summary
A method produces an applicator for applying liquid or pasty media (1), having a container (3) storing the medium (1), and an application element (5, 13) attached to the container (3) in a usage position such that the application element provides the medium (1) for application outside the container (3) by capillary action. A hose of thermoplastic plastic is extruded and inserted into a mold, forming a container (3) closed at the bottom by expanding the hose in the mold. The container (3) located in the mold is filled with the medium (1). The container (3) is separated from the hose to form an opening accessible at the top side of the container (3). The application element (5, 13) is put into the usage position by inserting the application element through the opening of the hose and fastening the application element (5, 13) while simultaneously creating a closure of the container (3) by moving movable mold parts of the mold.