Collapsible Inner Pouch Formation in Noncylindrical Liquid Dispensers
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Solution Overview
Problem
Existing liquid dispensers face challenges in fully utilizing noncylindrical outer container space and producing collapsible inner containers with uniform thickness, leading to inefficient use of space and poor collapsibility, especially in bulbous shapes.
Innovation Solution
A method involving a prefabricated outer container where pouch material is applied to the inner wall, forming a collapsible inner container ply that detaches from the outer container, allowing for the creation of a multi-ply pouch with specific material combinations for optimal detachment and space utilization, including the use of release and coloring materials for enhanced separation and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coextrusion process is used to create a double-walled hollow profile, then the inner container and outer container are produced together, but the design possibilities for shape are limited and noncylindrical shapes are difficult to produce
Solution Approach 1:
The production process is segmented into separate steps: first producing the outer container separately, then applying the pouch material to form the inner container. This segmentation allows independent optimization of each component and enables greater shape flexibility for the outer container while maintaining efficient production of the inner container.
Solution Approach 2:
The outer container is produced and prepared in advance, then the pouch material is applied to its inner wall to form the inner container. This preliminary action allows the outer container to be optimized for shape and function before the inner container is formed, enabling noncylindrical shapes and better space utilization.
2Ease of manufacture
If a cylindrical hollow profile is used for coextrusion, then the production process is simplified, but noncylindrical outer containers cannot be produced
Solution Approach 1:
The container system is segmented into an outer container and an inner pouch container formed separately. This allows the outer container to be produced in various noncylindrical shapes through different molding processes while the inner container is formed by applying pouch material to the inner wall, maintaining production simplicity for each component.
Solution Approach 2:
The production method changes from a single coextrusion process with fixed cylindrical geometry to a two-step process where the outer container shape can be varied (noncylindrical) and the inner container is formed by applying material to the inner wall, enabling shape parameter changes while maintaining manufacturing feasibility.
3Manufacturing precision
If the pouch wall thickness is increased in the region of smaller bottle cross section, then the minimum layer thickness is ensured, but the pouch becomes stiffened and collapsing is impaired
Solution Approach 1:
The pouch material is applied with varying thickness to different regions of the inner wall based on local requirements. In regions with smaller cross-section, the material forms a thinner layer to maintain collapsibility, while in regions with larger cross-section, the layer is thicker to ensure structural integrity. This local quality variation enables both uniformity where needed and flexibility where required.
Solution Approach 2:
The pouch wall thickness parameter is varied across different regions of the container. By controlling the material application process, the thickness parameter changes locally to match the geometric requirements of each region, ensuring minimum thickness for strength where needed while maintaining thin walls for collapsibility in other regions.
4Device complexity
If the inner container is inserted into the outer container separately, then the production steps are defined, but the available space in the outer container is not fully used
Solution Approach 1:
The production process merges the formation of the inner container with the outer container by applying the pouch material directly to the inner wall of the outer container. This merging allows the inner container to be formed to fit the exact contours of the outer container, maximizing space utilization while maintaining a defined production process structure.
Solution Approach 2:
The outer container is prepared in advance with its inner wall surface ready for material application. The pouch material is then applied to form the inner container that perfectly conforms to the outer container's shape, ensuring maximum space utilization. This preliminary preparation enables precise fitting and optimal volume usage.
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 method enables the production of liquid dispensers with noncylindrical outer containers that fully utilize internal space, ensuring efficient emptying and preventing contamination by eliminating the need for ventilation, thus maintaining product quality and consumer differentiation.
Implementation Method 1
the pouch material is applied in the form of a liquid or powder to the inner wall, where, after solidifying or fusing, it forms a ply of a wall of the inner container
Implementation Method 2
the pouch material is applied in the form of a liquid or powder to the inner wall, where, after solidifying or fusing, it forms a ply of a wall of the inner container
Implementation Method 3
at least one layer of a release material is applied to an inner wall of the outer container, where, after solidifying or fusing, it forms a release layer that promotes the detaching of the inner container from the inner wall of the outer container
Data Source
AI summary
A method for producing a containing system for a liquid dispenser having a dimensionally stable outer container and a collapsible inner container, in the form of a pouch, arranged within the outer container. The method includes starting from the outer container, at least one layer of a pouch material being applied to an inner wall of the outer container. For this purpose, the pouch material is applied in the form of a liquid or powder to the inner wall, where, after solidifying or fusing, it forms a ply of a wall, of the inner container. The ply detaches from the inner wall of the outer container when the inner container collapses.