Composite Container with Mixed Cross-Section Zones
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Solution Overview
Problem
Current composite containers, such as bag-in-box and jug-in-box types, face challenges in balancing rigidity and compactibility, with bag-type containers lacking rigidity and jug-type containers being heavy and expensive, while also requiring complex spout systems and difficult disposal.
Innovation Solution
A composite container design featuring a rigid, compressible inner-container with a circular and non-circular cross-section zones that fits snugly within a rectangular outer-container, produced through blow-molding and gas pressurization, allowing for efficient stacking, handling, and material savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If bag-type containers are used for inner-container, then the container can be stored flat and compressed after use, but the container lacks rigidity and tends to bulge requiring thicker outer-containers
Solution Approach 1:
The inner-container uses a composite structure combining rigid and compressible materials. The container is made from rigid plastic material (such as PET, PP, or HDPE) that provides structural strength and rigidity, eliminating the need for thicker outer-containers while maintaining the ability to be compressed after use.
Solution Approach 2:
The container design incorporates different structural properties in different zones. The main body maintains rigidity for strength, while the overall structure allows for compression after use. The cross-section varies between circular and non-circular zones to optimize both rigidity and compressibility in different areas.
2Strength
If jug-type containers are used for inner-container, then the container provides rigidity and robustness, but the container becomes much heavier and more expensive
Solution Approach 1:
The container uses optimized material parameters and thickness variations to achieve the required rigidity with minimal weight. The basis weight is controlled within a specific range (150-700 g/m2) to balance strength and weight requirements. The blow-molding process allows precise control of wall thickness to minimize material usage while maintaining structural integrity.
3Strength
If jug-type containers are used for inner-container, then the container provides robustness, but the container is slower to make and harder to dispose of after use
Solution Approach 1:
The container is manufactured using blow-molding technology, a pneumatic process that inflates a preform into the final container shape. This method is faster and more efficient than traditional jug manufacturing processes, improving production speed while maintaining robustness. The gas pressurization step further enhances the container structure efficiently.
4Volume of moving object
If bag-type containers are used for inner-container, then the container can be compressed after use, but complex supportive spout systems are required for decanting
Solution Approach 1:
The container uses a uniform rigid material structure throughout, eliminating the need for complex heterogeneous spout systems. The rigid plastic material maintains its shape and structural integrity, allowing for simple, integrated spout designs that do not require additional supportive structures.
5Strength
If the inner-container has only non-circular cross-section zones for contact with outer-container, then the container provides structural support, but the container cannot withstand bulging from internal pressure
Solution Approach 1:
The container cross-section strategically combines symmetric circular zones with asymmetric non-circular zones. The circular zones provide uniform pressure distribution and bulge resistance from internal pressure, while the non-circular zones optimize contact with the outer-container for structural support. This asymmetric combination of zone types resolves the contradiction between pressure resistance and structural support.
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 solution provides a lightweight, cost-effective container that maintains shape and strength, enabling easier handling and storage while reducing material usage and production costs, overcoming the limitations of existing container types.
Implementation Method 1
blow-molding the preform
Implementation Method 2
optionally, pressurizing the inner-container with gas
Data Source
AI summary
A composite container (10) comprising a rectangular cuboidal rigid outer-container (20) comprising a top and a bottom surface (21,22) connected by four side walls (23), and a single compressible, rigid inner-container (30) for containing a pourable product, said inner-container having a basis weight of from 150 g/m2 to 700 g/m2, and said inner container comprising a top (31), a bottom (32), and a closable opening (33) located at said top. The inner-container (30) comprises at least one zone (34) having a circular cross-section and at least two zones (35) having a non-circular cross-section, whereby said at least two zones (35) having a non-circular cross-section are in contact with the inner surface of said outer-container (20). The at least two zones (35) having a non-circular cross-section are separated by said at least one zone (34) having a circular cross-section.