Blow-Molded Part with Integrated Support Structure for Strength
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Solution Overview
Problem
Existing blow-molded parts, particularly expansion tanks, face challenges in meeting structural strength and dimensional accuracy requirements due to overpressures and underpressures, necessitating separate structural components that limit design flexibility.
Innovation Solution
A support structure is integrated into the blow mold, with a preform enclosing it, allowing a material-bonded connection during blow molding to create a base body, which can include weld ribs for reinforcement and interface geometries, eliminating the need for additional sealing elements and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate structural components are incorporated into the expansion tank to meet structural strength requirements, then the structural strength is improved, but the device complexity increases and design flexibility is limited
Solution Approach 1:
The patent combines the support structure with the base body by integrating it directly into the blow molding process. The support structure is formed simultaneously with the base body from the preform material, creating a unified component rather than assembling separate parts. This merging approach maintains structural strength while reducing device complexity and improving design flexibility.
Solution Approach 2:
The support structure serves multiple functions: it provides structural reinforcement, defines cavity geometry, and creates integrated mounting points. By designing the support structure to fulfill multiple roles within the single blow molding process, the patent eliminates the need for additional separate components, thereby reducing complexity while maintaining strength.
2Adaptability or versatility
If additional interface elements such as screw caps and valves are integrated into the expansion tank, then the functional requirements are met, but the device complexity increases and design freedom is restricted
Solution Approach 1:
Interface elements such as screw caps, valves, and mounting points are integrated directly into the base body during the blow molding process. The support structure is formed with built-in interface geometries that provide threading, sealing surfaces, and mounting features, eliminating the need for separate interface components and reducing overall device complexity.
3Ease of manufacture
If the preform is pressed against the cavity edges during blow molding, then the base body is formed, but seams are created on the blow molded part
Solution Approach 1:
The support structure is strategically positioned within the cavity to control the molding process. It provides localized support and guidance for the preform during pressing, ensuring proper alignment and distribution of material flow. This local structural intervention helps prevent seam formation at critical areas while maintaining ease of manufacture.
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 cost-effective production of blow-molded parts with highly accurate interface geometries and structural reinforcement, reducing manufacturing steps and components while ensuring media-tight connections and improved mechanical strength.
Implementation Method 1
the preform is inserted into the blow mold in such a way that the support structure is at least partially enclosed by the preform, then the blow mold is closed and a base body surrounding the support structure is produced from the preform by blow molding
Implementation Method 2
the blow mold is closed and a base body surrounding the support structure is produced from the preform by blow molding
Implementation Method 3
the base body connects with the support structure in a material-bonded and/or form-bonded manner during blow molding
Data Source
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AI summary
A method for producing a blow-molded part (1) in which a support structure (2) is provided and arranged in a blow mold (3), a preform (4) is inserted into the blow mold (3) such that the support structure (2) is at least partially enclosed by the preform (4), the blow mold (3) is then closed, and a base body (5) surrounding the support structure (2) is produced from the preform (4) by blow molding, wherein the base body (5) bonds to the support structure (2) during blow molding by a material bond and/or a form-fit bond. The invention further relates to a blow-molded part (1) comprising a base body (5) enclosing a cavity (15) and a support structure (2) arranged within the base body (5), wherein the base body (5) and the support structure (2) define the cavity (15), and wherein the base body (5) and the support structure (2) are materially bonded to one another.