Integral Pulp-Molded Bottle Molding for Glue-Free Liquid Storage
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Solution Overview
Problem
The existing process of pulp-molded bottle production is lengthy, costly, and environmentally unfriendly due to the use of glue, and paper products lose functionality when wet, limiting their ability to store liquids effectively.
Innovation Solution
A novel pulp molding process using an elastomer material with high temperature and pressure resistance, combined with a plastic liner, involves a pulp suction system, extrusion system, and hot-press molding system to create an integral pulp-molded bottle, reducing the need for glue and enhancing liquid storage capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional glue spreading and bonding process is used to assemble pulp-molded bottles, then the bottle structure can be formed, but the production process becomes lengthy and costly, and environmental protection is compromised due to difficulty in degradation of glue
Solution Approach 1:
The patent merges multiple separate components (bottle body, bottle mouth, bottle bottom) into a single integral pulp-molded bottle structure. By designing the mold to form all parts in one piece during a single molding cycle, the patent eliminates the need for subsequent glue spreading, pressing, and trimming operations, thereby simplifying the manufacturing process and reducing production time
Solution Approach 2:
The patent segments the molding process into distinct functional zones within a single mold structure, including a first mold cavity for the bottle body, a second mold cavity for the bottle mouth, and a third mold cavity for the bottle bottom. This segmentation allows each part to be formed simultaneously in its designated cavity while maintaining the integrity of the overall one-step molding approach
2Ease of manufacture
If traditional glue spreading and bonding process is used to assemble pulp-molded bottles, then the bottle structure can be formed, but the production cost increases and environmental protection is compromised
Solution Approach 1:
The patent extracts and eliminates the harmful glue component from the manufacturing process entirely. By designing the mold to form an integral bottle structure in one step, the patent removes the need for adhesive bonding, thereby eliminating the environmental pollution and degradation difficulties associated with traditional glue-based assembly methods
Solution Approach 2:
The patent changes the fundamental parameter of the manufacturing process from a multi-step assembly process requiring chemical adhesives to a single-step molding process using only mechanical forming. This parameter change transforms the production method to eliminate harmful chemical substances while maintaining structural integrity through the integral molded design
3Object-generated harmful factors
If pulp-molded bottles are made from 100% pulp material, then environmental protection is excellent and cost is reduced, but the bottles cannot store liquid for a long time due to quick wetting and loss of function
Solution Approach 1:
The patent creates a composite structure where a thin plastic liner is integrated within the pulp-molded bottle wall. This composite design combines the environmental benefits of pulp material with the liquid barrier properties of plastic, allowing the bottle to maintain both excellent environmental protection performance and reliable liquid storage capability for extended periods
Solution Approach 2:
The patent implements a nested structure where the plastic liner is embedded within the pulp-molded bottle wall cavity. The liner is formed first, then the pulp material is molded around it, creating a nested configuration where the inner plastic layer provides liquid resistance while the outer pulp layer provides structural integrity and environmental benefits
4Reliability
If plastic liner is added to enable liquid storage, then the liquid storage capability is improved, but the plastic content increases reducing environmental benefits
Solution Approach 1:
The patent applies partial action by using a thin plastic liner rather than a thick plastic layer. The liner is designed with minimal thickness sufficient to provide liquid barrier functionality, thereby achieving the required liquid storage capability while minimizing the amount of plastic material used and preserving environmental benefits
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 process results in a pulp-molded bottle that can store liquids for a long time with reduced plastic usage, achieving excellent environmental protection and cost-effectiveness by using 100% pulp-molded shells with a thin plastic liner, thereby minimizing plastic content by over 70%.
Implementation Method 1
an elastomer material having high temperature resistance and high pressure resistance is used in the design of a pulp molding mold
Implementation Method 2
an elastomer material having high temperature resistance and high pressure resistance is used in the design of a pulp molding mold
Implementation Method 3
a plastic liner is combined with a pulp-molded bottle shell by blow molding to improve the production mode of the existing pulp molding structure
Implementation Method 4
the pulp-molded bottle shell is made of 100% pulp-molded products to achieve excellent support strength, and the liner is made of 0.1-0.05 mm thick plastics to protect liquid
Data Source
AI summary
A mold for molding an integral pulp-molded bottle shell includes a pulp suction system, an extrusion system, and a hot-press molding system. A process for producing the pulp-molded bottle shell by the mold includes: forming a wet bottle preform in a pulp suction cavity through the pulp suction system; controlling the moisture content and thickness of the wet bottle preform by extrusion of an elastomer bag of the extrusion system; and injecting a pressurized fluid through an elastomer bag in the hot-press molding system, and performing hot-press drying in conjunction with a lower hot-press mold. An apparatus and process for producing a pulp-molded bottle having a plastic liner are provided. The apparatus includes an area for molding a pulp-molded bottle shell, an area for cutting the pulp-molded bottle shell, an area for storing a plastic bottle preform, and an area for performing loading of a liner.