Deep-Drawn Aluminum Container Embossed Side Walls
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Solution Overview
Problem
Existing manufacturing processes for deep-drawn containers with embossed side walls are inefficient, resulting in poor quality, durability issues, and increased costs due to the need for additional steps and materials, failing to meet optical and mechanical requirements for containers like bowls and mugs.
Innovation Solution
The side walls of deep-drawn containers feature embossing with roundings having a radius between 0.1 and 0.3 mm, and a height between half and twice the wall thickness, achieved without seams or grooves, using a combination of aluminum and sealing materials, allowing for clear contours and improved appearance without compromising mechanical stability or production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If flexible inserts (rubber, plastic) are used in the outer mold part to achieve embossing on side panels, then embossing can be achieved, but the quality of the result and durability of the inserts are insufficient for high production volumes
Solution Approach 1:
The patent changes the material parameters and geometric parameters of the mold components. Instead of using flexible rubber or plastic inserts, the invention employs a rigid outer mold part with integrated embossing features. The embossing is achieved through specific geometric design of the mold cavity that imprints the desired pattern directly during the forming process, eliminating the need for separate flexible inserts and their associated durability issues.
2Shape
If a split mold with additional movement of individual parts is used to emboss side panels, then embossing can be achieved, but the process complexity increases and is not accepted by business partners
Solution Approach 1:
The patent merges the embossing function into the main mold body by integrating the embossing cavity directly into the outer mold part. This eliminates the need for separate flexible inserts or split mold mechanisms with additional movements. The embossing process is combined with the primary forming operation, achieving both container formation and surface patterning in a single integrated mold structure.
3Shape
If embossing is applied to side walls during deep-drawing, then clear contours and improved appearance are achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent segments the mold cavity into distinct functional zones: a smooth forming zone for the main container body and an embossed zone with integrated patterning features on the outer mold part. This segmentation allows the embossing to be created as an inherent feature of the mold geometry rather than requiring separate manufacturing steps, thereby reducing overall manufacturing complexity while achieving the desired aesthetic effect.
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 enables cost-effective production of containers with clear, high-quality embossed side walls that maintain mechanical stability and appearance, reducing manufacturing complexity and enhancing handling and visual appeal, while maintaining the service life of the molded parts.
Implementation Method 1
deep-drawn containers made of at least one layer of aluminium and at least one layer of sealing material, with a bottom and side walls
Data Source
AI summary
The invention relates to a deep-drawn container made of at least one layer of aluminum with at least one layer of sealing material, which is located on the inside of the container after the deep-drawing process. The container has a base and side walls that form a sealing surface in a sealing plane at the circumferential upper edge and transition into a base at the circumferential lower edge. At least one side wall has an embossed pattern characterized in that the side wall in the embossed area has an inclination of at least 10° to the normal to the sealing surface, and that rounded edges with a radius between 0.1 and 0.3 mm are provided at the transition from the unembossed, normal area of the side wall to the embossed area. This ensures an optically flawless appearance, does not impair the embossing and forming processes, and does not shorten the service life of the die or punch.