Container Preform Molding With Closed-Loop Color Control

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Solution Overview

Problem

Existing systems for forming thermoplastic preforms suffer from inconsistent visual properties during production runs, particularly with recycled PET, leading to color inconsistencies and potential discolored preforms due to unadjusted additive dosing.

Innovation Solution

A system that includes a sensor to measure visual parameters, a control module to set and adjust additive let-down ratios, and a closed-loop feedback mechanism to ensure preforms meet target visual parameters, adjusting additive dosing in real-time to maintain consistency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If existing systems are used for forming preforms, then production can proceed, but visual consistency and color uniformity deteriorate during the production run

Engineering Contradiction:

Improvevisual consistencyVSAvoidproduction run duration

Core Design Contradiction:

Manufacturing precisionVSDuration of action of stationary object

Solution Approach 1:

The system employs a sensor to continuously monitor visual parameters of preforms during production and feeds this information back to a control module. The control module automatically adjusts additive dosing based on the feedback signal, maintaining visual consistency throughout extended production runs without manual intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes the dosing rate parameter of additives during the production process. By adjusting the amount of additive introduced into the thermoplastic resin in real-time based on visual parameter measurements, the system maintains consistent preform appearance despite variations in resin batches or processing conditions.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If manual monitoring and adjustment of additive dosing is performed, then visual parameters can be controlled, but labor requirements and production time increase

Engineering Contradiction:

Improvecolor consistencyVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system is self-regulating through automatic feedback control. The sensor continuously measures visual parameters, the control module processes this information, and the additive dosing is automatically adjusted without human intervention. This eliminates manual monitoring labor while maintaining color consistency throughout production.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical process of monitoring and adjusting additive dosing is replaced with an automated electronic control system. Sensors, control modules, and automated dosing mechanisms work together to substitute human labor with electronic measurement and control, improving both precision and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If additive dosing is not adjusted in real-time, then the system operates simply, but visual parameters drift outside acceptable ranges

Engineering Contradiction:

Improvesystem simplicityVSAvoidvisual parameter control

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

A sensor continuously measures visual parameters of formed preforms and provides feedback to a control module. This feedback loop enables automatic adjustment of additive dosing rates to maintain visual parameters within acceptable ranges, preventing drift without requiring complex manual intervention procedures.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts the dosing rate parameter of additives based on real-time visual parameter measurements. By changing dosing parameters automatically in response to measured variations, the system maintains precision while keeping the control logic relatively simple through proportional adjustment.

Inventive Principle:

Principle #35Parameter changes

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

Achieves consistent visual properties of preforms by continuously monitoring and adjusting additive levels, reducing labor, rejected preforms, and minimizing visual variations, ensuring high-quality final containers.

Implementation Method 1

measuring realized visual parameters of the preform with a sensor

Methodology Applied

Scientific EffectLight interaction: Absorption (EM radiation)

Data Source

PatentUS20250269571A1System for forming a container preform

Publication Date: 2025.08.28 AMCOR RIGID PACKAGING USA LLC

AI summary

A method for forming a preform or part including the following: dispensing an initial amount of an additive and a thermoplastic resin into an injection molding machine; forming the preform or part by operating a molding machine to inject the thermoplastic resin and the additive at the initial amount into a mold of the preform or part; measuring realized visual parameters of the preform or part; comparing the realized visual parameters to the target visual parameters and determining whether the realized visual parameters are within a predetermined acceptable range of the target visual parameters; if the realized visual parameters are outside the predetermined acceptable range of the target visual parameters, adjusting the initial amount of the additive to a modified amount estimated to achieve the target visual parameters; and forming an additional preform or part by operating the injection molding machine to inject the thermoplastic resin and the additive at the modified amount into the mold of the preform or part.