Injection Molded Composite Container with Flow-Controlled Cavity
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Solution Overview
Problem
Existing container manufacturing techniques lack efficient methods for forming injection-molded features with advanced-flow and delayed-flow sections to create strong, rigid structures with precise corner formations and resin distribution.
Innovation Solution
A container design featuring a base panel with side panels and multi-part flanges, where a band is injection-molded onto the flanges, and a forming tool with an injection cavity having advanced-flow and delayed-flow sections to direct resin flow effectively, forming a strong and rigid container with precise corner features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing container manufacturing techniques are used, then production can proceed with conventional methods, but the container lacks enhanced rigidity and precise corner formations
Solution Approach 1:
The patent employs composite construction by injection-molding resin onto the container blank to form an integrated structure with enhanced rigidity. The resin-infused blank creates a composite material system combining the original blank material with resin, producing a structurally superior container with reinforced corners and flanges.
Solution Approach 2:
The injection cavity is divided into distinct flow sections (advanced-flow and delayed-flow sections) that control resin distribution to different areas of the container. This segmentation allows precise resin placement in critical areas like corners and flanges while managing manufacturing complexity through controlled injection patterns.
2Manufacturing precision
If resin is injected uniformly across the container, then injection process is simple, but resin distribution is uneven and corner formations are imprecise
Solution Approach 1:
The injection cavity is designed with different flow characteristics in different regions: the advanced-flow section delivers resin quickly to corners and flanges requiring high precision, while the delayed-flow section provides controlled resin distribution to other areas. This local differentiation of flow properties achieves precise resin distribution without requiring overly complex injection equipment.
3Reliability
If the injection cavity has uniform cross-sectional area, then the injection process is straightforward, but resin flow rate is inconsistent and structural integrity is compromised
Solution Approach 1:
The injection cavity incorporates variable cross-sectional area that changes along the flow path. The advanced-flow section has larger cross-section for high flow rate to corners, while the delayed-flow section has smaller cross-section for controlled resin delivery. This dynamic variation in geometry ensures consistent resin flow rates and reliable structural integrity throughout the container.
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 enables the creation of containers with enhanced rigidity and precise corner formations, ensuring effective resin distribution and improved structural integrity through the controlled flow of injection-molded material.
Implementation Method 1
The injection cavity is for receiving liquid resin and directing liquid resin around at least a portion of the perimeter of the blank
Data Source
AI summary
A structure is injection molded onto a group of panels to form a container. The container has a tray and an injection-molded feature. The tray has a plurality of side panels that extend at least partially around, and at least partially define, a cavity of the container. The tray has a plurality of multi-part flanges with at least one of the multi-part flanges including a lower flange portion and an upper flange portion. The injection-molded feature has band that is injected molded onto the lower flange portion and the upper flange portion. An injection-molded strip extends along and at least partially defines the corner of the container. The strip extends downward from the inner portion of the band in the elongate corner of the container. A tool is also disclosed for forming the container.