Blow Molded Container Flange Formation via Intermediary Mold Frame
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Solution Overview
Problem
The high transport and handling costs associated with large-volume plastic container production, particularly due to the weight and size of closed containers, necessitate an economical method for manufacturing and assembling these containers.
Innovation Solution
A method involving a tubular preform made of thermoplastic plastic being guided over a mold frame within a blow mold, forming a peripheral flange when the mold is closed, allowing for the production of open container shells that can be easily stacked and transported, and subsequently connected to form a closed container at the destination using matching flanges and seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large-volume closed containers are manufactured and transported as complete units, then product functionality is ensured, but transport and handling costs increase significantly
Solution Approach 1:
The container is divided into two separate open container shells (halves) that are manufactured independently and transported separately. These shells are then assembled at the destination to form the complete closed container, reducing transport costs while maintaining functionality
Solution Approach 2:
The two container shells are pre-formed with integrated flanges during the blow molding process, preparing them for easy assembly at the destination without requiring additional manufacturing steps
2Reliability
If conventional blow molding produces closed containers, then container integrity is achieved, but transport efficiency deteriorates
Solution Approach 1:
The container is segmented into two open shells with flanges that can be transported efficiently and assembled later, improving transport efficiency while maintaining integrity through proper sealing mechanisms
3Adaptability or versatility
If other manufacturing processes like deep drawing or rotational molding are used, then alternative production methods are explored, but cost-effectiveness and flange production capability are lost
Solution Approach 1:
The blow molding process is enhanced with a mold frame that serves multiple functions: forming the container shell, creating the flange structure, and enabling easy separation of the two halves, making it versatile and cost-effective
Solution Approach 2:
The mold frame acts as an intermediary tool that enables the blow molding process to produce containers with flanges, combining the advantages of blow molding with flange formation capability that other processes lack
4Shape
If injection molding is used to produce containers with flanges, then flange formation is achieved, but tooling costs and machine size requirements increase dramatically
Solution Approach 1:
The mold frame serves as an intermediary that enables flange formation during blow molding, avoiding the need for complex injection molding tools and large machines while achieving the same flange shape
5Ease of operation
If container shells are produced with flanges for easy assembly, then assembly simplicity is improved, but manufacturing process complexity increases
Solution Approach 1:
The mold frame performs multiple functions including forming the container shell, creating the flange structure, and enabling easy separation of halves, simplifying the overall process despite the added component
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 reduces transport costs and simplifies handling by enabling efficient stacking and assembly of large-volume containers, while maintaining economic and inexpensive manufacturing through the blow molding process, minimizing material waste and tooling costs.
Implementation Method 1
a tubular preform made of plastic in the thermoplastic state is fed to at least one blow mold
Implementation Method 2
When the blow mold closes, the mold frame, in conjunction with the edge of the blow mold, forms a circumferential flange on the outer edge of the container shell
Data Source
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AI summary
The invention relates to a method and a device for producing large-volume container trays (10, 12) of plastic. A tubular preform (36) is guided over a mold frame (32) which is facing two blow molds (26, 28). During the closure of the blow molds (26, 28), an encircling flange (14, 16) is formed on the outer edge of the container trays (10, 12). After blow molding, the container trays (10, 12) are cut free from the mold frame (32) along said mold frame.