Double-Layer Bottle In-Mold Lamination for Wrinkle-Free Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing squeeze bottles with foam interlayers in double-layer structures face assembly instability, poor appearance due to wrinkles, and inadequate cold preservation, complicating production and reducing thermal insulation effectiveness.
Innovation Solution
A double-layer extruded bottle manufactured via in-mold lamination, featuring an elastomer insulation layer on the inner cup and a thermoplastic elastomer or rubber layer on the outer cup, integrated through in-mold processes, with pattern layers for decoration and insulation, forming a stable interlayer gap for enhanced thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If foam is added to the interlayer gap to improve thermal insulation, then the cold preservation effect is improved, but the assembly difficulty increases and the appearance quality deteriorates due to wrinkles
Solution Approach 1:
The patent merges the insulation layer with the inner cup by integrating them into a single molded component. The insulation layer is formed as an integral part of the inner cup during the molding process, eliminating separate assembly steps and ensuring stable positioning without wrinkles or loose fits.
Solution Approach 2:
The insulation layer is pre-formed and integrated into the inner cup structure before final assembly. By incorporating the insulation layer during the initial molding process rather than adding it separately, the patent prevents assembly difficulties and appearance defects that would result from post-assembly attachment.
2Temperature
If foam is added to the interlayer gap to improve thermal insulation, then the cold preservation effect is improved, but the appearance quality deteriorates due to surface wrinkles
Solution Approach 1:
The insulation layer and inner cup are merged into a single integrated component through co-molding. This integration ensures that the insulation layer maintains a smooth, wrinkle-free surface that conforms precisely to the inner cup geometry, eliminating appearance defects while preserving thermal insulation performance.
Solution Approach 2:
The insulation layer is formed in its final smooth configuration during the preliminary molding process. By establishing the wrinkle-free surface quality during initial manufacturing rather than through subsequent assembly operations, the patent ensures high appearance quality is maintained throughout the product lifecycle.
3Temperature
If a double-layer structure with interlayer gap is used to reduce heat transfer, then the thermal insulation performance is improved, but the assembly complexity increases
Solution Approach 1:
The patent combines the insulation layer and inner cup into a single molded unit, reducing the double-layer structure from two separate components requiring assembly to one integrated component. This merger maintains the thermal insulation functionality of the interlayer gap while eliminating assembly complexity.
Solution Approach 2:
The inner cup is segmented to include an integrated insulation layer as a distinct functional zone within the single component. This segmentation allows the insulation layer to be molded with precise geometry and positioning, simplifying the overall structure by eliminating the need for separate assembly of multiple layers.
4Temperature
If separate insulation layers are attached to inner and outer cups, then the thermal insulation performance is improved, but the production cost increases
Solution Approach 1:
The patent merges the insulation layer formation with the inner cup molding process, combining what would be separate manufacturing operations into a single integrated process. This reduction in the number of manufacturing steps directly lowers production costs while maintaining the thermal insulation performance of the integrated insulation 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
The integrated insulation layers improve thermal insulation performance, maintain liquid temperature, and reduce production costs by ensuring adhesion and durability, while allowing for decorative patterns, enhancing user experience.
Implementation Method 1
The first insulation layer is integrally formed with the inner cup by an in-mold lamination process
Implementation Method 2
An interlayer gap is formed between the inner cup and the outer cup... to reduce heat transfer
Data Source
AI summary
A double-layer extruded bottle comprises an inner cup, an outer cup connected to the inner cup, an interlayer gap disposed between the inner cup and the outer cup, and a first insulation layer disposed in the interlayer gap and on an outer peripheral surface of the inner cup. The first insulation layer is integrally formed with the inner cup by an in-mold lamination process. A manufacturing method for the bottle includes forming the first insulation layer and a second insulation layer by in-mold lamination, pattern printing, punching and shaping, blow molding, and assembly and welding of the inner and outer cups. The extruded bottle has a double-layer structure that improves the heat preservation performance. The integrated molding method shortens the production cycle and reduces the production cost. Decorative patterns can be printed on outer surfaces of the insulation layers.