Blow Molded Container Corner Strength via Layered Protrusions
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Solution Overview
Problem
Blow-molded plastic containers with sudden changes in surface geometry at corners are prone to deformation due to increased spacing between walls, which compromises material strength and uniformity, making them vulnerable to external impacts.
Innovation Solution
A corner design featuring a predetermined pattern of affixed protruding parts on inner and outer layers, where the layers are separated elsewhere, enhancing corner strength by distributing impact across both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spacing between walls at corner portion is increased to avoid adhesion and ensure uniform thickness, then manufacturing reliability is improved, but corner strength and resistance to deformation deteriorates
Solution Approach 1:
The corner portion is segmented into multiple layers (first layer, second layer, third layer) with distinct functions. The first and second layers form the container walls with increased spacing, while the third layer provides structural reinforcement at the corner, distributing impact forces across multiple segments rather than relying on a single thickened wall.
Solution Approach 2:
The corner portion employs a composite structure combining multiple layers of different thicknesses and configurations. The first layer has greater thickness than the second layer, and the third layer is positioned between them to create a composite corner structure that optimizes both spacing for manufacturing reliability and overall strength through layered composition.
2Strength
If wall thickness at corner portion is increased to improve strength, then resistance to deformation is improved, but material uniformity and adhesion quality deteriorates
Solution Approach 1:
Different regions of the container wall have different thicknesses optimized for their specific functions. The first layer at the corner portion has greater thickness for strength, while the second layer has lesser thickness. This local differentiation allows the corner to have enhanced deformation resistance without compromising material uniformity in the main wall sections.
Solution Approach 2:
The wall structure is segmented into multiple layers with varying thicknesses. The first layer provides structural strength at the corner, the second layer maintains uniform thickness for the main container body, and the third layer bridges between them, ensuring each segment has the appropriate thickness for its specific requirement.
3Ease of manufacture
If spacing between walls is increased at corner portion, then adhesion problems are avoided, but impact absorption and dent resistance deteriorates
Solution Approach 1:
The corner structure uses a composite of three layers where the first and second layers maintain increased spacing to prevent adhesion, while the third layer positioned between them provides impact absorption and dent resistance. This composite arrangement allows the spacing benefits for manufacturing while compensating for the reduced impact resistance through the intermediate reinforcing layer.
Solution Approach 2:
The corner portion is divided into three functional segments: the first layer forming the outer wall, the second layer forming the inner wall with spacing to prevent adhesion, and the third layer as an intermediate structural element that provides impact absorption, distributing harmful impact forces across multiple segments.
Data Source
AI summary
A blow molded container includes a main member (20) forming a tool cavity. The main member (20) has an inner surface. The main member (20) further contains at least one corner portion (30) and at the corner portion (30), the main member (20) includes at least a first layer (40) and a second layer (42). The first layer (40) forming the inner surface, and the first layer (40) and the second layer (42) are affixed together along a predetermined pattern while being separated from each other elsewhere. The first layer (40) is formed with a first protruding part (143) along the predetermined pattern, and the second layer (42) is formed with a second protruding part (145) along the predetermined pattern. The first protruding part (143) and the second protruding part (145) are affixed together.