Distortion Printed Thermoplastic Container Substrate
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Solution Overview
Problem
The complexity and cost of labeling processes for plastic containers, particularly due to the need for precise and high-temperature-resistant equipment to handle irregular shapes, result in increased manufacturing costs and reduced line speed, necessitating a more efficient method for forming labeled containers at high speed and low cost.
Innovation Solution
A container formed from a one-piece distortion printed thermoplastic substrate, where the closed end and container wall are made from a common thermoplastic substrate, allowing for simplified manufacturing and integration of printing directly onto the substrate before forming, reducing the need for complex labeling equipment and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate labeling equipment is used to apply labels to containers after formation, then labeling can be performed on irregularly shaped containers, but the equipment complexity increases and manufacturing line speed decreases
Solution Approach 1:
The patent combines the labeling function with the container formation process by integrating printing capabilities directly into the extrusion blow molding line. The print module is positioned to print on the container surface during formation, merging two previously separate operations (container making and labeling) into a single integrated process, thereby reducing equipment complexity while maintaining versatility
Solution Approach 2:
The printing operation is performed preliminarily during container formation rather than as a separate post-formation step. By printing on the container while it is being formed in the mold, the labeling action occurs in advance of the traditional separate labeling operation, eliminating the need for complex downstream labeling equipment
2Adaptability or versatility
If separate labeling equipment is used to apply labels to containers, then labeling can be performed, but the manufacturing cost increases
Solution Approach 1:
The patent merges the labeling operation with the container formation process by integrating a print module into the extrusion blow molding line. This consolidation eliminates the need for separate labeling equipment and operations, reducing capital investment and manufacturing costs while maintaining the ability to label irregularly shaped containers
Solution Approach 2:
The integrated print module provides universal labeling capability that works for all container types produced on the line, regardless of shape or size. This multi-functional approach replaces the need for multiple specialized labeling machines, thereby reducing overall manufacturing cost while maintaining adaptability
3Manufacturing precision
If labeling equipment is designed to handle irregular container shapes, then precise labeling can be achieved, but the equipment needs to be customized and complex
Solution Approach 1:
The print module is designed with dynamic positioning capabilities that allow it to adapt to different container shapes and sizes during the formation process. The printing surface can move and adjust its position relative to the container, enabling precise label placement on irregular shapes without requiring custom-designed equipment for each container type
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 the production of labeled containers with reduced manufacturing complexity and cost, while maintaining high-speed production by integrating printing directly onto a flat web before forming, thus eliminating the need for separate labeling operations and enhancing the container's structural integrity.
Implementation Method 1
a first image printed on a flat web that is distorted into a second image on the container
Data Source
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AI summary
A container including an open end; a closed end opposing the open end; a container wall extending longitudinally between the closed end and the open end about a longitudinal axis; an end seam extending at least partially across the closed end; and a longitudinal overlapping seam extending from the end seam, a portion of the overlapping seam extending longitudinally along the container wall from the closed end to a neck portion proximal the open end; wherein a common one-piece distortion printed thermoplastic substrate forms both the closed end and the container wall.