Cream Pot Housing Wall Segmentation for Cycle Time Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cream jar manufacturing processes are inefficient and visually unappealing due to high material thickness and complex manufacturing methods, leading to long cycle times and unsatisfactory optical appearance.
Innovation Solution
A cream jar design featuring a housing wall formed by two thin, translucent or transparent webs spaced apart by an air gap, which reduces manufacturing cycle times and creates a visually appealing optical appearance by minimizing reflection edges and enhancing the perceived thickness of the housing wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a thick-walled housing is used to achieve a visually appealing appearance, then the optical appearance is improved, but the manufacturing cycle time increases significantly
Solution Approach 1:
The housing wall is segmented into two separate thin webs (inner web and outer web) spaced apart by an air gap. Each web has a thickness of 1.5-4 mm, while the combined structure creates the appearance of a thick wall (6-12 mm). This segmentation allows each thin web to be manufactured quickly via injection molding while the air gap provides the desired visual thickness.
Solution Approach 2:
An air gap serves as an intermediary element between the inner and outer webs. This air gap not only separates the two thin webs but also contributes to the perceived wall thickness and provides optical reflection surfaces that enhance the visual appearance. The air gap acts as a mediator that combines the manufacturing advantages of thin walls with the aesthetic benefits of thick walls.
2Strength
If a thick-walled housing is manufactured using traditional methods, then the structural integrity is maintained, but the manufacturing complexity and cost increase
Solution Approach 1:
The housing is segmented into two separate thin-walled webs rather than manufacturing one thick-walled structure. This segmentation simplifies the injection molding process, reduces cycle times, and lowers manufacturing costs while maintaining structural integrity through the distributed strength of two webs connected by a base and rim.
Solution Approach 2:
The housing employs a composite structure combining two thin plastic webs with an air gap, creating a composite wall system that achieves the structural properties of a thick wall without using thick material. This composite approach leverages the strengths of multiple thin elements to provide adequate structural support while simplifying manufacturing.
3Ease of manufacture
If a single thick wall is used, then the manufacturing process is simpler in concept, but the cycle time becomes very long due to material thickness
Solution Approach 1:
The single thick wall concept is segmented into two thin webs with an air gap. This segmentation maintains the conceptual simplicity of a single housing structure while dramatically reducing the actual material thickness that must be molded, thereby reducing cycle time from potentially 30-60 seconds to 5-15 seconds per cycle.
Solution Approach 2:
The solution transitions from a one-dimensional thickness problem to a three-dimensional structure by introducing an air gap dimension. Instead of reducing wall thickness in one dimension, the invention creates depth through the air gap, maintaining the appearance of thickness while minimizing actual material volume and molding time.
4Illumination intensity
If translucent or transparent material is used for the housing, then the visual appeal is enhanced, but reflection edges become more prominent
Solution Approach 1:
The reflection problem is solved by transitioning from a flat single surface to a multi-dimensional structure with two parallel surfaces separated by an air gap. This creates multiple reflection planes that distribute and soften reflected light, reducing the prominence of individual reflection edges while maintaining the aesthetic benefits of transparent or translucent material.
Solution Approach 2:
The housing creates multiple optical copies of reflection surfaces through the two parallel webs. Instead of one strong reflection edge from a single wall, the double-web structure creates two softer, distributed reflection surfaces that reduce the harshness of individual reflections while maintaining visual appeal through the transparent or translucent material.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The cream jar has an external housing (1), which is provided with a housing base (2) and housing walls, whose inner wall surface (4') surrounds a receiving chamber. The outer wall surface (6') of a cup-shaped insert (6) rests against or near the inner wall surface. An outer bar (3) forms the outer wall surface (3') and the inner bar (4) forms the inner wall surface.