Deformable Container Bottom Thermal Control Method
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Solution Overview
Problem
Hot filling of plastic containers with contents exceeding the glass transition temperature leads to mechanical strength issues due to softening, resulting in uncontrolled deformations and instability, particularly when cooling, which affects both aesthetics and mechanical integrity, and existing solutions like deformable panels or membrane bottoms either limit shape freedom or impose manufacturing stresses and energy consumption.
Innovation Solution
A method involving a container with a deformable zone and a mechanical pusher that moves between retracted and deployed positions, where the pusher's movement is controlled based on temperature measurements to ensure reliable deformation and reduce energy consumption, using a thermal camera or pyrometer to determine when to move the membrane back and apply force, optimizing temperature thresholds for stable locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the container is heat-set to increase mechanical strength during filling, then the container can withstand hot filling temperatures, but the container cannot resist stresses from content contraction during cooling, resulting in uncontrolled deformations
Solution Approach 1:
The patent introduces a dynamic deformable bottom that can change its configuration from extended to retracted based on the thermal state of the container. This dynamic element allows the container to adapt to thermal stresses during cooling, preventing uncontrolled deformations while maintaining structural integrity during hot filling.
Solution Approach 2:
The patent changes the physical state parameter of the bottom membrane by controlling its temperature relative to the glass transition temperature of the plastic material. By monitoring temperature and only actuating the deformable bottom when T < Tg, the system exploits parameter changes in material properties to achieve stable locking.
2Reliability
If deformable panels are equipped on the container to monitor deformations, then deformation monitoring is achieved, but the freedom of shape of the container is limited, affecting appearance
Solution Approach 1:
The patent uses a flexible membrane bottom that can be actuated between extended and retracted configurations. This flexible film approach provides deformation control capability while maintaining aesthetic appearance, as the membrane can be positioned to create a visually appealing flat bottom surface when retracted.
3Strength
If a membrane bottom is equipped with a mechanical pusher to reduce internal volume and acquire rigidity, then structural rigidity is improved, but manufacturing stresses are imposed and the membrane may be unstable in its returned position
Solution Approach 1:
The patent implements a feedback control system that monitors the temperature of the container and uses this information to determine when to actuate the deformable bottom. The control unit compares the measured temperature with the glass transition temperature and only activates the pusher when appropriate, preventing manufacturing stresses and instability.
Solution Approach 2:
The patent performs the deformation control action at the optimal moment by monitoring temperature and actuating the deformable bottom only when T < Tg. This preliminary thermal conditioning ensures the material is in the appropriate state for stable locking, preventing subsequent instability.
4Stability of the object's composition
If containers are allowed to cool freely for a long time to ensure stable membrane positioning, then deformation control is improved, but productivity is reduced
Solution Approach 1:
The patent uses real-time temperature monitoring with a feedback control system to determine the optimal moment for actuating the deformable bottom. This eliminates the need for prolonged free cooling, as the system continuously monitors thermal state and acts immediately when conditions are appropriate, maintaining high productivity.
Solution Approach 2:
The patent replaces the passive mechanical cooling approach with an active thermal monitoring and control system. Instead of relying on time-based cooling, the system uses temperature sensors and control units to actively manage the thermal state, enabling precise timing of the deformable bottom actuation.
5Productivity
If forced cooling is applied to containers to enable timely membrane turnaround, then productivity is maintained, but energy consumption increases
Solution Approach 1:
The patent allows the container to cool naturally using its own thermal energy dissipation to the environment, rather than requiring external forced cooling systems. The deformable bottom is actuated at the optimal moment when natural cooling has achieved the appropriate temperature, eliminating the need for energy-consuming forced cooling while maintaining productivity.
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 enhances the reliability of packaging production by controlling deformable zone operations, reducing energy consumption, and ensuring stable membrane locking, thereby improving mechanical strength and aesthetic appearance while maintaining productivity.
Implementation Method 1
a phase for monitoring the temperature of the stoppered container, comprising an operation for measuring the temperature of the stoppered container by means of a thermal camera or a pyrometer
Data Source
AI summary
Method for forming a packaging (2) from a container (1) that has a body (5), a neck (8), and a bottom (6), the container (1) having a deformable zone (15) with an extended configuration in which the zone (15) projects toward the outside of the container (1), with a retracted configuration in which the zone (15) projects toward the inside of the container (1), with this method including the following operations:filling the container (1) with a hot product;closing in an airtight manner the thus filled container (1);measuring the temperature of the stoppered container (1);comparing the measured temperature to a preset threshold value;if the measured temperature is less than or equal to the threshold value, moving the deformable zone (15) back toward its retracted position.