Bi-Injected Flair Preforms With Non-Stick Layer Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing Flair and Flair-type liquid delivery systems face challenges in efficiently manufacturing pre-forms that prevent fusion and bonding between inner and outer containers made of different materials or with the same material, especially when using different materials with varying molding temperatures, and require additional processing steps to ensure air-tight seals and prevent liquid leakage.
Innovation Solution
The use of bi-injection molding processes and non-stick coatings to create pre-forms, where the outer pre-form is fashioned first, followed by the inner pre-form, and connection methods such as spin welding, ultrasonic welding, and crimping are employed to ensure the pre-forms are connected at the top and bottom, with mechanisms like air pressure release mechanisms to prevent bonding and ensure air-tight seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bi-injection molding process is used to manufacture pre-forms, then manufacturing efficiency is improved and additional processing steps are eliminated, but the complexity of the molding process increases
Solution Approach 1:
The patent combines the molding of inner and outer pre-forms into a single bi-injection molding process. The outer pre-form is molded first, then the inner pre-form is molded within the same mold cavity without removing the outer pre-form, eliminating separate manufacturing steps and improving productivity.
Solution Approach 2:
The inner pre-form is molded nested within the outer pre-form's mold cavity. The mold design allows the inner pre-form to be formed inside the space created by the outer pre-form, enabling both components to be manufactured in a nested sequence within the same molding cycle.
2Ease of manufacture
If non-stick coating is applied to prevent bonding between pre-forms, then the pre-forms can be successfully separated after molding, but an additional coating step is required
Solution Approach 1:
A non-stick coating is applied as an intermediary layer on the mold surface or pre-form surface between the inner and outer pre-forms. This coating acts as a mediator that prevents direct bonding between the two pre-forms during molding, allowing easy separation afterward.
3Adaptability or versatility
If inner and outer pre-forms are made from the same material, then material selection is simplified, but the pre-forms may fuse and bond together during molding
Solution Approach 1:
When the same material is used for both pre-forms, local quality differentiation is achieved through applying non-stick coating to specific surfaces or regions where bonding would occur. This allows the bulk material to remain uniform while preventing localized bonding at critical interfaces.
4Adaptability or versatility
If different materials with varying molding temperatures are used for inner and outer pre-forms, then material properties can be optimized for specific functions, but the molding temperatures must be carefully controlled to prevent bonding
Solution Approach 1:
Different materials with distinct molding temperature characteristics are selected for inner and outer pre-forms to optimize their respective properties. The bi-injection molding process controls temperature parameters sequentially, molding the first pre-form at its optimal temperature, then adjusting to the second material's optimal temperature for the inner pre-form.
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 method results in efficient pre-form manufacturing without additional processing steps, ensuring air-tight seals and preventing liquid leakage, allowing for hot filling of liquids up to 90°C without deforming the outer container, and preventing refilling through one-way valves.
Implementation Method 1
such a pre-form can be made by a bi- injection process, using the same mold. In such exemplary embodiments, first the outer pre-form can be fashioned, and then the inner pre-form can be molded through a center hole provided at the bottom of the outer pre-form
Implementation Method 2
In such a process, a non-stick coating can be sprayed on the surface that will be between the pre-forms, where the second perform will touch the first one
Implementation Method 3
connection methods such as spin welding, ultrasonic welding, and crimping are employed to ensure the pre-forms are connected at the top and bottom
Implementation Method 4
connection methods such as spin welding, ultrasonic welding, and crimping are employed to ensure the pre-forms are connected at the top and bottom
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Improved pre-forms for Flair and Flair-type applications are presented. In exemplary embodiments of the present invention, if two different materials which do not bond together are used to make a pre-form, then such a pre-form can be made by a bi- injection process, using the same mold. In such exemplary embodiments, first the outer pre-form can be fashioned, and then the inner pre-form can be molded through a center hole provided at the bottom of the outer pre-form. The two pre-forms are then connected to each other. The two materials can be different, such as PET and a polyolefin or polyamide, or for example, they can even be the same, such as PET/PET, if steps are taken to prevent their bonding during the molding of the second pre-form layer. In such a process, a non-stick coating can be sprayed on the surface that will be between the pre-forms, where the second perform will touch the first one, and after such application, the second container can be molded, also in a 2C process. The order of manufacture can be either outer then inner, or inner then outer, in various exemplary embodiments. If outer then inner, the non-stick coating can be sprayed on the inside of the first molded outer perform, followed by molding of the inner preform. If the reverse, the non-stick coating is sprayed on the outside of the first molded inner perform, then followed by the molding of the outer perform. The material from which the inner container is made, the degree of shrinkage it will experience relative to the outer container, and the concomitant maximum hot fill temperature it can thus support, can all be designed for a given application, use or range of uses.