Container Manufacturing: Integrating Packaging Components in Single Mold
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Solution Overview
Problem
The existing methods for manufacturing containers with additional packaging components, such as caps or spouts, require separate formation and assembly, increasing process complexity and cycle time due to the need for transferring preliminary products between molding and blowing units, which reduces efficiency.
Innovation Solution
A method where a preliminary product with a collar and integrally molded further packaging component is formed in a single mold, using injection molding to create a connecting feature that allows the packaging component to be permanently attached, simplifying the assembly process and reducing cycle time by integrating the packaging component directly into the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate formation and assembly of packaging components is used, then manufacturing flexibility is improved, but process complexity increases
Solution Approach 1:
The patent merges the formation of the container body and the packaging component into a single injection molding process. The mold includes a first cavity for forming the container body and a second cavity for forming the packaging component, both filled from a common material supply. This combining of operations eliminates separate formation and assembly steps, reducing process complexity while maintaining the ability to produce different container and component combinations by simply changing the mold configuration.
2Manufacturing precision
If preliminary product is cooled down before transfer, then deformation during transfer is prevented, but cycle time increases
Solution Approach 1:
The patent combines the injection molding of the preliminary product and the subsequent blowing operation into a single continuous process without intermediate cooling and transfer steps. The preliminary product is formed and then immediately blown while still in the mold, eliminating the time-consuming cooling and transfer operations while maintaining dimensional stability through the controlled molding process.
Solution Approach 2:
The patent performs the injection molding of the preliminary product with precise dimensional control as a preliminary action, creating a structure that is ready for immediate blowing without requiring extensive cooling. The mold design and injection parameters are optimized to produce a preliminary product that maintains its shape and dimensions, allowing direct transfer to the blowing operation without intermediate cooling steps.
3Reliability
If manual assembly or specialist machinery is used for attaching components, then attachment reliability is improved, but productivity decreases
Solution Approach 1:
The patent merges the formation of the container body and the packaging component with their attachment into a single integrated injection molding process. The mold design includes features that automatically connect the two components during molding, eliminating the need for separate assembly operations. This integration maintains attachment reliability through precise mold-designed connections while dramatically increasing productivity by eliminating manual or machine-assisted assembly steps.
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 approach simplifies the assembly process, reduces cycle time, and enhances process efficiency by allowing the packaging component to be formed and attached in a single step, eliminating the need for separate assembly and transfer, thereby improving production line efficiency.
Implementation Method 1
heating thermoplastic material to a sufficient temperature
Implementation Method 2
injected into a first cavity to make a preliminary product
Implementation Method 3
cooling the preliminary product to a temperature low enough to allow ejection
Implementation Method 4
heating the preliminary product to a sufficient temperature
Implementation Method 5
blow molding the preliminary product in a second cavity to form a wall and base, which together form a void volume
Data Source
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AI summary
The present relates to a method of manufacturing a preliminary product and container (1), having a further packaging component attached to the collar.