Blow-Molded Structure With Freely Oriented Compression Elements
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Solution Overview
Problem
Conventional blow-molding processes are limited in incorporating compression molded elements, as they can only be oriented parallel to the plane of the parting line, restricting their location and configuration within the blow-molded structure.
Innovation Solution
The integration of movable tool portions within the mold allows for the creation of compression molded elements that can be located anywhere in the blow-molded structure, including non-parallel orientations, using a tool that cooperates with the mold to form these elements simultaneously with the blow-molded structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional compression molded elements are used in blow-molded structures, then they can be formed using standard molding processes, but they are limited to orientations parallel to the parting line plane
Solution Approach 1:
The mold includes movable portions that can be positioned in different locations and orientations within the mold cavity. These movable portions allow the compression molded element to be formed in various orientations including non-parallel orientations relative to the parting line plane, thereby providing flexibility in element placement while maintaining manufacturability through controlled movement during the molding process
Solution Approach 2:
The mold is divided into stationary portions and movable portions, where the movable portions can be independently positioned. This segmentation allows different sections of the mold to perform different functions - the stationary portions provide structural support and definition, while the movable portions enable flexible positioning and orientation of the compression molded element within the blow-molded structure
2Device complexity
If compression molded elements are limited to parallel orientations with the parting line, then the molding process remains simple, but the structural flexibility and design freedom are reduced
Solution Approach 1:
The introduction of movable portions in the mold allows for dynamic adjustment of element orientation and position without requiring completely different molding processes. The movable portions can be actuated during the molding cycle to achieve various configurations, providing design flexibility while maintaining a relatively simple overall process framework
Solution Approach 2:
The mold design with movable portions serves multiple functions: it can form compression molded elements in various orientations, accommodate different element locations, and maintain compatibility with standard blow-molding processes. This multi-functionality increases adaptability without proportionally increasing device complexity
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 enables the creation of blow-molded structures with integral compression molded elements that can be positioned freely, enhancing structural flexibility and strength by allowing elements to be formed in various configurations and locations, including non-parallel planes, within the structure.
Implementation Method 1
a tool disposed within the mold and comprising: a first compression element; and a second compression element, wherein the first and second compression elements are configured and arranged so that one of the compression elements is movable relative to the other compression element, and the compression elements collectively define a gap into which plastic inside the mold can be deposited
Data Source
AI summary
In one example, a structure is provided that includes a plastic body having a unitary, single-piece construction. The plastic body further includes a substantially hollow interior, and a parting line that extends around a portion of the perimeter of the structure. The structure also includes a solid compression molded element that is integral with the plastic body. The solid compression molded element is configured and arranged such that the parting line is not connected to the solid compression molded element.