Double-Walled Container Air Intake via Mold Clamping
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Solution Overview
Problem
Conventional methods for manufacturing double containers with a rigid outer and flexible inner layer struggle to create an external air introducing opening efficiently and reliably, leading to high processing costs and difficulties in mass production, as the positioning of the air introduction hole is inconsistent due to variations in blow pressure and temperature during the molding process.
Innovation Solution
The method involves using a split mold with mating surfaces that clamp the rigid outer and flexible inner layers at horizontally opposed positions, forming a protruding tub portion and outer layer slits to create a reliable air introduction opening without damaging the inner layer, allowing for easy separation and consistent production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional blow-molding methods are used to form the air introduction hole, then the molding process is simple, but the positioning of the air introduction hole becomes inconsistent due to variations in blow pressure and temperature
Solution Approach 1:
The patent pre-forms protrusions on the outer layer during the initial blow-molding process, before the air introduction hole needs to be created. These protrusions serve as predetermined guides that ensure consistent positioning of the air introduction hole subsequent to the molding process, eliminating positioning variability caused by blow pressure and temperature fluctuations.
Solution Approach 2:
The patent introduces protrusions as intermediary structural elements between the outer layer and the air introduction hole formation process. These protrusions act as mediators that guide the cutting or piercing tool to create the air introduction hole at a precise, consistent location, thereby decoupling the hole positioning from the variable blow-molding parameters.
2Ease of manufacture
If the outer layer is cut to expose the inner layer for air introduction, then air can be introduced into the space between layers, but the inner layer may be damaged during the cutting process
Solution Approach 1:
The patent pre-forms protrusions on the outer layer that extend beyond the inner layer's perimeter. This preliminary structuring creates a safety margin that prevents cutting tools from contacting or damaging the inner layer during the air introduction hole creation process, ensuring inner layer integrity while maintaining manufacturing simplicity.
Solution Approach 2:
The protrusions on the outer layer serve as a preliminary protective measure against potential damage to the inner layer. By extending the outer layer beyond the inner layer boundaries, the design preemptively prevents harmful cutting actions from reaching the inner layer, thereby protecting it before the air introduction process occurs.
3Manufacturing precision
If the flexible inner container contacts the inner surface of the rigid outer container during manufacturing, then proper positioning is achieved, but separation of the layers becomes difficult after content consumption
Solution Approach 1:
The patent applies different structural characteristics to different regions of the container walls. The outer layer has protrusions in specific local areas that extend beyond the inner layer, creating localized separation zones. This allows the layers to maintain contact for positioning during manufacturing while having predetermined separation paths in specific locations where easy separation is needed after content consumption.
Solution Approach 2:
The patent segments the container wall structure by creating protrusions that extend beyond the inner layer perimeter. This segmentation creates distinct regions: areas where layers remain in contact for structural integrity and positioning, and protruding areas that serve as separation zones. This segmented approach resolves the contradiction between maintaining contact for manufacturing precision and enabling easy separation for post-use functionality.
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 easy and reliable formation of an external air introducing opening in double containers, reducing processing costs and facilitating mass production by maintaining consistent positioning and separation of the layers, thus preventing oxidation of the remaining content.
Implementation Method 1
a parison P is disposed between a pair of partial molds (60) of a split mold, and the parison P is expanded by blowing air into the parison P
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
The present invention is a double-walled container manufacturing method in which when a pair of partial molds is brought towards each other to be assembled to form a split mold, at least a portion of the mating surfaces of the pair of partial molds clamp a parison at two side portions that are at horizontal positions facing each other. The method is able to manufacture the container easily with a molding device that does not differ significantly from the past and, in a double-walled container obtained from a relatively rigid outer container and a flexible inner container the volume of which can change according to the amount of contents filled inside said outer container, an opening for introducing outside air can be formed very easily and reliably at a lower cost than the processing cost of prior art.