Delamination Container Preform Recessing for Clean Air Hole Formation
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Solution Overview
Problem
The challenge in manufacturing delamination containers using a blow molding method of a hot parison type is the difficulty in forming an air introduction hole in the outer layer without penetrating the inner layer, due to the high melting point difference between the resin materials and thermal deformation during injection molding.
Innovation Solution
A manufacturing method and apparatus that utilize a two-stage injection molding process to form a preform with a recess portion in the outer layer, followed by stretch blow molding, ensuring the air introduction hole penetrates the outer layer and exposes the inner layer, using resin materials with different melting points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the blow molding method of hot parison type is applied to manufacture delamination container, then productivity and environmental load reduction are improved, but it becomes extremely difficult to manufacture due to thermal deformation of inner layer
Solution Approach 1:
The patent changes the temperature parameter by cooling the inner layer to a temperature not higher than the melting point of the outer layer resin before injecting the outer layer. This parameter change prevents thermal deformation of the inner layer while enabling the hot parison blow molding process to proceed, thus resolving the contradiction between productivity improvement and manufacturing difficulty
Solution Approach 2:
The patent applies preliminary cooling action to the inner layer before the outer layer injection. By pre-cooling the inner layer to an appropriate temperature, the patent prevents subsequent thermal deformation when the hot outer layer resin is injected, making the hot parison blow molding process manufacturable
2Reliability
If air introduction hole is formed in outer layer during blow molding, then delamination function is improved, but risk of penetrating inner layer increases
Solution Approach 1:
The patent changes the temperature parameter of the inner layer by cooling it to not higher than the melting point of the outer layer resin. This temperature control ensures that when the air introduction hole is formed in the outer layer, the inner layer remains solid and intact, preventing penetration while ensuring reliable delamination function
Solution Approach 2:
The patent uses temperature control as an intermediary parameter to manage the relationship between outer layer hole formation and inner layer integrity. By mediating through temperature, the patent enables hole formation in the outer layer without compromising the inner layer
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 allows for reliable formation of air introduction holes in the outer layer, enabling efficient delamination of the inner and outer layers while maintaining the integrity and appearance of the delamination container.
Implementation Method 1
the surface of the inner layer in contact with the resin material of the outer layer is melted and thermally deformed
Data Source
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AI summary
In a manufacturing method for a delamination container, in a first injection molding step, a first recess portion is formed by a first protrusion portion in at least part of a first layer. In a second injection molding step, a second recess portion which penetrates the first layer and through which a surface of a second layer is exposed is formed in a preform by inserting a second protrusion portion into the first recess portion. In a blow molding step, the second recess portion is stretched to form an air introduction hole in an outer layer of the delamination container.