Delamination Container Thermal Deformation Prevention
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Solution Overview
Problem
The challenge in manufacturing delamination containers lies in the thermal deformation of the inner layer due to the higher melting point of the outer layer resin material during the injection molding process, making it difficult to use a blow molding method of a hot parison type, and the need for improved grippability and ease of molding while considering delamination.
Innovation Solution
A two-layer delamination container design with a first layer made from a resin with a higher melting point and a second layer with specific properties for content stability, combined with a manufacturing method involving two-stage injection molding and stretch blow molding to form a preform with recesses and air introduction holes, ensuring easy one-handed handling and effective delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a blow molding method of hot parison type is used to improve manufacturing efficiency and reduce environmental load, then productivity is improved, but the inner layer undergoes thermal deformation and melting due to contact with high-temperature outer layer resin material
Solution Approach 1:
The patent changes the temperature parameter by cooling the inner layer to a temperature lower than the melting point of the outer layer resin material before injecting the outer layer. This temperature parameter change prevents thermal deformation and melting of the inner layer while enabling the use of hot parison blow molding method for improved productivity
Solution Approach 2:
The patent applies preliminary cooling action to the inner layer before the injection of outer layer resin material. By pre-cooling the inner layer to below the melting point of the outer layer material, the patent prevents subsequent thermal deformation that would occur during hot parison blow molding, thus enabling both high productivity and dimensional accuracy
2Reliability
If the outer layer resin material is set with a higher melting point for content stability, then reliability is improved, but the inner layer surface melts and thermally deforms during injection molding
Solution Approach 1:
The patent changes the temperature parameter of the inner layer by cooling it to below the melting point of the outer layer resin material. This enables the use of high-melting-point outer layer materials for content stability while preventing thermal deformation of the inner layer during injection molding
Solution Approach 2:
The patent applies local quality differentiation by creating a temperature gradient between the inner and outer layers. The inner layer is specifically cooled to a temperature state that prevents melting, while the outer layer maintains its high melting point properties for content stability, thus resolving the contradiction between reliability and manufacturing precision
3Ease of operation
If the container shape is optimized for one-handed grippability, then ease of operation is improved, but molding complexity increases
Solution Approach 1:
The patent segments the container into distinct functional zones: a grip portion with specific geometric features for one-handed handling, a body portion for content storage, and a neck portion for dispensing. This segmentation allows the grip portion to be optimized for ergonomics while the overall structure remains suitable for injection molding
Solution Approach 2:
The patent applies local quality by providing specific geometric features (such as circumferential grooves or protrusions) only in the grip portion of the container, while maintaining a simple cylindrical shape in the body and neck portions. This localized complexity improvement maintains ease of molding while enhancing one-handed grippability
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
The solution enhances the grippability and usability of the container while maintaining ease of molding and delamination, allowing for stable content discharge without thermal deformation and reducing environmental impact.
Implementation Method 1
an injection molding step to a blow molding step are continuously performed
Implementation Method 2
blow molding method of a one-stage hot parison type
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
A delamination container includes an outer layer formed from a first resin material, and a bag-shaped inner layer provided on the inner peripheral side of the outer layer and formed from a second resin material different from the first resin material, and the outer layer is provided with a hole for introducing air into a gap between the outer layer and the inner layer. The delamination container includes a neck portion having an opening communicating with an inside of the inner layer, a shoulder portion continuously extending in the radial direction from the neck portion, a body portion having a bottomed cylindrical shape, and a constricted portion interconnecting the shoulder portion and the body portion. The diameter of the outer peripheral edge of the shoulder portion is 40 mm or more and 55 mm or less, the axial length from the outer peripheral edge of the shoulder portion to a constricted bottom portion which has the smallest diameter in the constricted portion is 12 mm or more and 25 mm or less, and a ratio of the diameter of the constricted bottom portion to the diameter of the outer peripheral edge of the shoulder portion is 0.80 or more and 0.93 or less.