Double-Walled Vessel Injection Mold with Integrated Sealing
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Solution Overview
Problem
Double-walled drinking vessels with ultrasonic welding connections often have leakages, allowing air and water to ingress into the hollow space, leading to condensation and an undesirable appearance during dishwasher use.
Innovation Solution
An injection mold and method for producing double-walled drinking vessels with a concentric design, using an index plate with cores to form and join the outer and inner containers via thermoplastic resin injection, creating a tighter bond and eliminating the need for additional assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to join the outer and inner containers, then mechanical connection is achieved, but the weld seam is not absolutely tight allowing air and water to ingress into the hollow space
Solution Approach 1:
The patent merges the joining operation with the molding operation by injecting joint material directly into the hollow space during the injection molding process. This combines two separate operations (molding containers and joining them) into a single integrated process, eliminating the need for separate ultrasonic welding equipment and operations while achieving absolutely tight seals that prevent water and air ingress.
Solution Approach 2:
The patent performs the joining action preliminarily during the molding process itself. The joint material is injected into the hollow space between the outer and inner containers while they are still in the mold, sealing the space before the product leaves the mold. This preliminary sealing action ensures absolute tightness from the start, preventing any subsequent water or air ingress issues.
2Productivity
If the outer and inner containers are molded separately and then joined, then manufacturing flexibility is maintained, but additional assembly steps are required increasing production time
Solution Approach 1:
The patent combines multiple operations into a single injection molding cycle: forming the outer container, forming the inner container, and injecting joint material to seal the hollow space all occur in one continuous process within the same mold. This merging of operations eliminates separate assembly steps and significantly reduces production cycle time despite the increased mold structure complexity.
Solution Approach 2:
The injection mold is designed with multi-functionality to perform several operations: it forms both the outer and inner containers, provides pathways for injecting both the container material and the joint material, and enables the sealing operation all within a single device. This universal mold design consolidates multiple functions into one system, improving productivity despite the inherent complexity.
3Reliability
If water ingress into the hollow space is prevented, then appearance is maintained, but connection tightness must be absolutely ensured
Solution Approach 1:
The patent applies preliminary action by injecting the joint material into the hollow space between the outer and inner containers during the molding process, sealing the space before the product is removed from the mold. This preliminary sealing ensures absolute tightness from the outset, completely preventing water ingress and maintaining appearance throughout the product lifecycle.
Solution Approach 2:
The patent converts the potential harm of water ingress into a benefit by using the joint material injection process to create an absolutely tight seal. The same injection mechanism that forms the containers also seals the hollow space, transforming a potential failure mode (water ingress) into a guaranteed protective feature (absolute seal integrity).
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 results in a watertight bond between the containers, reducing the likelihood of water ingress and simplifying the production process by completing the vessel within the mold, thus enhancing efficiency and appearance.
Implementation Method 1
a first cavity injection gate for injecting a mold material into the first cavity for forming the outer container, the second cavity having a second cavity injection gate for injecting a mold material into the second cavity for forming the inner container
Implementation Method 2
the first cavity having a further injection gate for injecting a joint material for joining the outer container and the inner container
Data Source
AI summary
An injection mold for producing a double walled drinking vessel includes first and second mold portions. The first mold portion forms a first and second cavities corresponding to the outer shape of the outer container and the outer shape of the inner container, respectively. The first and second cavities are located concentrically with respect to a central axis. An index plate is rotatable and axially movable along the central axis relative to the first mold portion. The index plate includes a first core and a second core. The first cavity has a first cavity injection gate for injecting mold material into the first cavity for forming the outer container. The second cavity has a second cavity injection gate for injecting mold material into the second cavity for forming the inner container. The first cavity has a further injection gate for injecting joint material for joining the outer and inner containers.