Ergonomic Integral Handle Assembly for Blow-Moulded Containers
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Solution Overview
Problem
Blow-moulded containers with integral handles suffer from discomfort due to pressure on the index finger when lifted, especially with larger volumes, and are aesthetically inferior due to a wasteful material volume and the 'I-beam' handle structure.
Innovation Solution
A method and design for a handle with a loop of orientable material extending between upper and lower connection regions, featuring a uniform cross-section that widens to a maximum width, along with strengthening elements, to reduce strain and improve aesthetics, including a straight lower section and an arcuate section with integrated strengthening elements to fit comfortably around the index finger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the handle has a uniform cross-section throughout its length, then the material usage is optimized and manufacturing is simplified, but the handle causes discomfort and excessive pressure on the index finger when lifting larger capacity containers
Solution Approach 1:
The handle cross-section is varied along its length: uniform in the lower portion (for manufacturing efficiency and material optimization) and gradually widening in the upper portion (for comfort when lifting). This local variation in geometry allows the handle to simultaneously achieve material efficiency and ergonomic comfort by adapting the cross-sectional area to different functional requirements along its length.
2Strength
If the handle uses a webbed I-beam structure, then the structural strength is adequate, but the aesthetic appearance is inferior and material usage is wasteful
Solution Approach 1:
The handle cross-sectional parameters are changed along its length: the upper portion has a gradually widening cross-section that provides both aesthetic appeal and sufficient structural strength, while the lower portion has a uniform cross-section that is more material-efficient. This parameter variation allows the handle to achieve adequate strength throughout while improving appearance in the visible upper region.
3Ease of operation
If the handle cross-section is increased at the upper connection region, then comfort when lifting is improved, but the material volume and manufacturing complexity increase
Solution Approach 1:
The handle cross-section is increased only in the upper portion where it is needed for comfort during lifting, while maintaining a uniform, simpler cross-section in the lower portion. This partial application of the cross-section increase principle achieves the ergonomic benefit without unnecessarily increasing material volume or manufacturing complexity throughout the entire handle length.
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 reduces strain on the index finger when lifting containers and optimizes material usage, providing a more comfortable and aesthetically pleasing handle design for larger capacity containers.
Implementation Method 1
rotating the preforms during transport along the transportation system past an array of preform heating elements
Data Source
AI summary
A method of controlling a preform for stretch blow-moulding a container with an integrally formed handle; the preform comprising, a body portion and the integrally formed handle; the preform transferred from a perform supply source to a blow moulding die for blowing the container; the method including the steps of passing the preform through a preform handle orientating apparatus, transferring the preform to a preform transportation system, maintaining orientation of the preform handle imposed by the perform handle orientating apparatus during transfer to the perform transportation system and transfer to the blow moulding die, rotating the preforms during transport along the transportation system past an array of preform heating elements while shielding the integrally formed handle from excessive exposure to the heating elements, transferring the preform from the transportation system to the blow moulding die, and wherein the handle comprises a loop of orientable material extending between an upper connection region and a lower connection region on the body portion of the preform; characterised in that the handle has a generally uniform cross section from proximate the lower connection region to a gradually widening cross section approaching the upper connection region; the cross section reaching and maintaining a maximum width proximate the upper connection region.