Blow Molded Article Wall Foaming for Recyclable Visual Effects
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Solution Overview
Problem
Existing blow molding processes struggle to provide articles with aesthetic qualities such as color, translucence, opacity, and dimensional effects while maintaining recyclability and structural integrity, often requiring additives that compromise recycling and increasing production costs.
Innovation Solution
A method involving foaming predetermined portions of the preform walls to create aesthetic regions with oblong voids in a predetermined pattern, allowing for unique visual effects without compromising recyclability or structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If additives are used to provide aesthetic qualities (color, translucence, opacity), then visual effects are improved, but recyclability deteriorates
Solution Approach 1:
The patent uses foamed regions with oblong voids in the preform wall to create aesthetic effects. These voids act as porous structures that provide visual effects including translucence, opacity, and dimensional depth without requiring chemical additives. The foamed regions are created through controlled expansion of gas bubbles within the preform material during or after molding, achieving the desired aesthetic qualities while maintaining the material's recyclability.
Solution Approach 2:
The patent changes the physical parameters of the preform wall by creating foamed regions with specific void structures. By controlling the size, distribution, and orientation of the oblong voids, the patent achieves various aesthetic effects such as translucence and opacity. This parameter-based approach modifies the physical structure rather than adding chemical substances, thereby preserving recyclability while enhancing visual properties.
2Illumination intensity
If foaming is applied to create aesthetic regions, then visual effects are improved, but structural integrity deteriorates
Solution Approach 1:
The patent applies local quality by creating foamed regions only in specific portions of the preform wall rather than throughout the entire structure. The oblong voids are strategically positioned in the outer portion of the wall, leaving the inner portion dense and intact. This localized foaming provides the desired aesthetic effects in visible areas while maintaining structural integrity in load-bearing areas.
Solution Approach 2:
The patent applies partial action by foaming only a portion of the preform wall thickness. The foamed regions are confined to the outer portion of the wall, with the inner portion remaining unfoamed. This partial foaming approach creates sufficient aesthetic effects in the visible outer layer while preserving the structural strength of the inner wall structure.
3Ease of manufacture
If preform manufacturing steps are simplified, then production cost is reduced, but aesthetic options are limited
Solution Approach 1:
The patent applies preliminary action by incorporating the aesthetic features directly into the preform during its manufacturing process. The foamed regions with oblong voids are created in the preform before the final blow molding step, allowing the aesthetic effects to be built-in rather than added later. This integration into the preform stage simplifies the overall manufacturing process and reduces costs while providing diverse aesthetic options.
Solution Approach 2:
The patent enables diverse aesthetic options by controlling the parameters of the foamed regions in the preform. By adjusting the size, distribution, orientation, and depth of the oblong voids, the patent can create various visual effects including different degrees of translucence, opacity, and dimensional depth. This parameter control allows for aesthetic customization without requiring complex additional manufacturing steps.
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
The method enables the creation of aesthetically pleasing blow molded articles with controlled visual effects, maintaining recyclability and structural integrity by limiting foaming to specific wall portions, thus avoiding the need for additives that detract from recycling.
Implementation Method 1
foaming at least a portion of the walls of the preform to form one or more foamed regions within an outermost 60% of the wall
Implementation Method 2
stretching the preform to form a blow molded article
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
Article (100) having a body (12) portion including one or more walls (150, 270, 30) surrounding an interior space (36). The one or more walls (150, 270, 30) have an inner surface (132, 32, 35), an outer surface (133, 33), a wall (150, 30) thickness (T1, T2, T3), a transparent portion, and one or more aesthetic regions (137, 1) having oblong voids provided between the inner surface (132, 32, 35) and the outer surface (133, 33) within an outermost 70% of the wall (150, 30), and the one or more aesthetic regions (137, 1) are provided in a predetermined pattern (154, 54).