Fibre-Based Container with Evacuation Holes for Blow Molding
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Solution Overview
Problem
Current blow molding processes for producing containers, especially for carbonated beverages, face challenges in minimizing plastic usage and recycling efficiency due to insufficient barrier properties and material separation complexities.
Innovation Solution
The method involves forming a fibre-based shell with evacuation holes, particularly in the centre portion and rim of the bottom, to facilitate air escape during blow molding, reducing the risk of shell damage and enabling easier separation of plastic and fibre materials for recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a fibre-based shell is used to minimize plastic usage, then plastic reduction is achieved, but the shell is prone to damage during blow molding due to trapped air
Solution Approach 1:
The fibre-based shell is designed with porous structure that allows air to escape during the blow molding process. The pores enable air evacuation while maintaining the structural integrity of the shell, resolving the contradiction between minimizing plastic usage and preventing shell damage during manufacturing.
2Weight of moving object
If plastic and fibre-based materials are combined in a container, then lightweight packaging is achieved, but separation for recycling becomes complex
Solution Approach 1:
The container is designed as separable components: a plastic liner and a fibre-based shell. The blow molding process naturally separates these materials, with the plastic being injected into and then removable from the fibre shell. This segmentation enables easy separation for recycling, resolving the contradiction between lightweight packaging and recycling complexity.
3Loss of substance
If the fibre-based shell is made thin to minimize material usage, then material reduction is achieved, but the shell lacks sufficient rigidity
Solution Approach 1:
The container uses a composite structure combining a thin fibre-based shell with a plastic liner. The fibre shell provides the outer structure and rigidity, while the plastic liner provides the barrier properties and structural support. This composite approach allows the fibre shell to be made thin for material reduction while maintaining sufficient rigidity through the combined structure.
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 minimizes plastic usage and enhances recycling efficiency by reducing the risk of shell damage and improving material separation, making the containers more suitable for recycling and reducing plastic waste.
Implementation Method 1
forming a fibre-based shell with evacuation holes, particularly in the centre portion and rim of the bottom, to facilitate air escape during blow molding
Data Source
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AI summary
The present invention relates to a method for forming a container. The method comprises providing a container-shaped, fibre-based shell (1) in a negative mold (2) matching the shape of the shell, wherein the shell has a non-flat shaped bottom (3) with an evacuation hole (4, 5) in a lowest portion of the bottom of the shell, and blow molding a preform (6) inside the shell such that a plastic lining is formed on an inner surface of the shell and an outer surface of the shell is pressed against a wall surface of the negative mold. A container is also presented.