Double-Wall Blow Molding Shrinkage Separation
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Solution Overview
Problem
Existing double containers require complex assembly steps and shape limitations due to the need for inserting an inner container into an outer container, which restricts their design and functionality.
Innovation Solution
A synthetic resin double container is created using a direct blow molding process, where a space is formed between non-adherent outer and inner layers with different mold shrinkage factors, allowing for easy separation without additional assembly steps, by selecting resins and molding conditions to ensure a peeling force greater than the adherent strength, and incorporating a cracked pinch-off portion for efficient separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inner container is inserted into the outer container with a fitting cap, then the double container structure is achieved, but the neck requires a large bore diameter and additional assembly steps are needed
Solution Approach 1:
The patent merges the inner and outer containers into a single integrated molded structure. The blow-molded container includes an outer wall and an inner wall formed in one molding operation, eliminating the need for separate assembly steps and fitting caps while maintaining the double-wall insulating structure
Solution Approach 2:
The container is segmented into multiple walls (outer wall and inner wall) with air spaces between them, creating a double-wall structure that provides thermal insulation while being formed as a single integrated piece through blow molding processes
2Ease of manufacture
If the inner container is inserted into the outer container, then the double container structure is achieved, but additional positions, parts, or steps for assembling are required
Solution Approach 1:
The patent combines multiple manufacturing operations into a single blow molding process. The outer wall, inner wall, and air spaces are all formed simultaneously in one molding operation, eliminating the need for separate assembly steps, fitting caps, and insertion operations
Solution Approach 2:
The single blow molding process performs multiple functions: it forms the outer container structure, creates the inner container structure, generates the insulating air spaces, and produces the final assembled double-wall container all in one operation
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 process simplifies the molding of double containers by eliminating the need for complex assembly and allows for the formation of a space between layers, enhancing design flexibility and functionality, such as heat insulation and decorative features.
Implementation Method 1
a space is formed between the outer layer and the inner layer made of synthetic resins that are mutually non-adherent, thus allowing both layers to be left in a detached state due to a difference in mold shrinkage factors between the two layers revealed in a direct blow molding step
Data Source
AI summary
The technical problems of this invention are to overcome a limitation in the aspect of the shape of conventional synthetic resin double containers comprising an inner container and an outer container and to solve a problem of additional steps required to assemble the outer and inner containers. A principle means taken to solve these problems comprises a double container made by a direct blow molding process wherein a space is formed between the outer layer and the inner layer made of synthetic resins that are mutually non-adherent, thus allowing both layers to be left in a detached state due to a difference in mold shrinkage factors between the two layers during the direct blow molding step.