Core Rod Coating for Thin-Walled Preform Production

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Solution Overview

Problem

The existing process for producing thin-walled preforms requires significant capital investment and time due to the need for new injection moulds and core rods, as manufacturers struggle to reduce wall thickness while maintaining high technical performance.

Innovation Solution

A process involving the modification of existing core rods by depositing a metallic compound onto their surface, increasing the body shaping portion's diameter, which allows for the production of thinner walled preforms without the need for new moulds, using chip removal and surface finishing techniques to achieve the desired dimensions and adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If new injection moulds with larger diameter core rods are acquired to produce thin-walled preforms, then the wall thickness of preforms is reduced, but the capital investment costs increase considerably

Engineering Contradiction:

Improvewall thickness of preformVSAvoidcapital investment cost

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The invention changes the physical state and dimensions of the core rod by depositing a metallic compound coating that increases the core rod's diameter. This parameter change allows the existing core rod to function as a larger diameter core rod, enabling thin-walled preform production without acquiring new equipment.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite structure by depositing a metallic compound coating onto the existing core rod. This composite approach combines the base core rod material with the metallic coating to achieve the desired increased diameter and functional properties, avoiding the need for a completely new core rod.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If new injection moulds with larger diameter core rods are acquired to produce thin-walled preforms, then the wall thickness of preforms is reduced, but the time required for replacement increases

Engineering Contradiction:

Improvewall thickness of preformVSAvoidtime for mould replacement

Core Design Contradiction:

Weight of moving objectVSLoss of time

Solution Approach 1:

The coating process is applied to the existing core rod in advance, transforming it before use. This preliminary action prepares the core rod to function with the required larger diameter, eliminating the need for time-consuming replacement during production schedules.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By changing the physical dimensions of the existing core rod through coating deposition, the invention allows the same core rod to serve multiple functions across different production requirements, reducing the frequency of replacements and associated downtime.

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If the diameter of core rod body shaping portion is increased to produce thinner walled preforms, then the preform wall thickness is reduced, but the core rod dimensions must be changed

Engineering Contradiction:

Improvewall thickness of preformVSAvoidcore rod diametrical dimensions

Core Design Contradiction:

Weight of moving objectVSManufacturing precision

Solution Approach 1:

The invention precisely controls the coating deposition process to achieve the exact increase in core rod diameter needed. By controlling the coating thickness and uniformity, the final diametrical dimensions of the core rod body shaping portion are precisely adjusted to match the requirements for thin-walled preform production.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of using traditional mechanical machining methods to increase core rod diameter, the invention employs a deposition process that builds material onto the surface. This substitution allows for more precise dimensional control and reduces material removal waste compared to mechanical enlargement methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 cost-effective and rapid modification of core rods to produce thin-walled preforms, reducing investment costs and time, while maintaining mechanical properties and adhesion, allowing for the production of lighter containers with high technical performance.

Implementation Method 1

depositing means to deposit said metallic compound onto the core rod

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS10836087B2Process to coat an injection mould

Publication Date: 2020.11.17 SIPA SOCIETA INDUSTRIALIZZAZIONE PORGETTAZIONE E AUTOMAZIONE SPA

AI summary

A process to increase the diameter of a core rod (1) of an injection mould for preforms, wherein the core rod (1) has a moulding surface (2) divided in a neck finish portion (3) and a preform body portion (4), comprises the steps of: a) grinding or milling a layer from the surface of the preform body portion (4) of the core rod, b) depositing a metallic compound onto the ground portion to make a coating, c) removing the excess of coating material to bring the coated surface to a predetermined superficial roughness and to diametrical dimensions greater than the original surface profile (14) to reduce the thickness of the lateral wall of the moulded preform.