Blow-Molded Container Wall Layout for Concentrated Oxygen Scavengers
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Solution Overview
Problem
Conventional plastic blow-molded containers with unconcentrated additives, such as oxygen scavengers, increase production costs and hinder recycling due to yellowing and delamination issues, while two-stage production methods are inefficient and costly.
Innovation Solution
A method for manufacturing containers with a concentrated barrier material, such as an oxygen scavenger, positioned towards the center line of the container wall, using a two-phase injection system to minimize additive usage and enable efficient recycling by avoiding additives in scrap material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unconcentrated additives such as oxygen scavengers are included in conventional plastic blow-molded containers, then shelf life is improved, but production cost increases and recyclability is hindered due to yellowing and delamination
Solution Approach 1:
The patent applies local quality by concentrating the oxygen scavenger additive in a specific intermediate portion of the preform wall rather than distributing it uniformly throughout. This localized concentration achieves the necessary shelf life protection while minimizing the total amount of expensive additive required, thereby reducing production costs.
Solution Approach 2:
The patent changes the concentration parameter of the additive by creating a concentrated intermediate portion with higher additive content positioned between the inner and outer portions. This parameter change allows achieving effective oxygen scavenging with less total additive, reducing cost while maintaining shelf life.
2Reliability
If unconcentrated additives are used in conventional containers, then shelf life is improved, but recyclability deteriorates due to yellowing caused by additives and catalysts
Solution Approach 1:
By localizing the additive concentration in the intermediate portion away from the inner surface, the patent reduces yellowing effects while maintaining oxygen scavenging functionality. The concentrated additive is positioned to protect the product without causing excessive yellowing that would hinder recycling.
Solution Approach 2:
The patent positions the concentrated additive portion to skip over the critical inner surface area where yellowing would most directly affect product visibility and recycling quality, while still providing effective oxygen scavenging protection.
3Ease of manufacture
If two-stage production equipment is used to manufacture blow-molded containers, then manufacturing capability is improved, but production efficiency decreases and cost increases
Solution Approach 1:
The patent merges the preform injection molding and the concentration of oxygen scavenger additive into a single integrated process step. The two-phase injection system combines both functions in one operation, eliminating the need for separate post-processing steps and improving production efficiency while maintaining manufacturing capability.
Solution Approach 2:
The patent performs the concentration of oxygen scavenger additive during the preform injection molding process itself, before the blow molding step. This preliminary action eliminates the need for separate subsequent processing steps, improving overall production efficiency.
4Reliability
If high concentration of oxygen scavenger is used to improve shelf life, then protective function is enhanced, but cost increases due to high additive content
Solution Approach 1:
The patent applies local quality by concentrating the oxygen scavenger in the intermediate portion rather than distributing it throughout the entire preform. This localized approach achieves effective shelf life protection with minimal total additive content, reducing cost while maintaining protective function.
Solution Approach 2:
The patent uses partial action by concentrating the additive only in the intermediate portion rather than throughout the entire preform. This partial concentration achieves sufficient oxygen scavenging protection while minimizing the quantity of expensive additive required.
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
Reduces production costs and maintains shelf life by minimizing additive content, enhances recyclability by eliminating yellowing and delamination, and optimizes scrap material reuse.
Implementation Method 1
a first material is injected into a mold to form a top portion of a preform; the first material and a second material are injected into the mold to form a bottom portion of the preform
Implementation Method 2
The preform is disposed in a second mold. The preform is blow molding into a finished container
Data Source
AI summary
A method for manufacturing a container includes injecting a first material into a first mold to form a top portion of a preform. The first material and a second material are injected into the first mold to form a bottom portion of the preform. The preform is disposed in a second mold. The preform is blow molded into a finished container.