Liquid Container Head Space Formation via Segmented Nozzle
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Solution Overview
Problem
Conventional liquid blow molding methods face issues with air entrainment in the liquid supply path, leading to instability in molding conditions and moldability, as the liquid inside the container is initially filled with air from the preform, which complicates the formation of a precise headspace.
Innovation Solution
A liquid container manufacturing method using a nozzle unit with a blow nozzle, discharge rod, and gas supply port, where the liquid is discharged from the container under closed liquid supply path conditions, and pressurized gas is used to assist in forming a headspace by increasing pressure until a set value is reached, then stopping gas supply to prevent over-pressurization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the liquid inside the container is drawn in through the blow nozzle to create negative pressure and introduce air into the container to form the headspace, then the headspace can be formed, but air entrained in the liquid supply path causes deterioration in stability of molding conditions and moldability
Solution Approach 1:
The liquid supply path is divided into two separate paths: a first liquid supply path for supplying liquid to the preform during blow molding, and a second liquid supply path for discharging liquid from the container to form the headspace. This segmentation prevents air entrained during blow molding from entering the discharge path, thereby maintaining molding condition stability while enabling precise headspace formation.
Solution Approach 2:
The blow nozzle serves as an intermediary structure that includes both a liquid supply port (opening-closing port) for the first liquid supply path and a discharge port for the second liquid supply path. By positioning the discharge port below the liquid supply port and using the opening-closing body to control flow, the system mediates between the need to fill the container with liquid and the need to discharge liquid for headspace formation without air contamination.
2Ease of manufacture
If the liquid blow molding method is used to manufacture the liquid container, then the manufacturing cost is reduced by omitting the filling step, but air entrainment in the liquid supply path complicates the formation of a precise headspace
Solution Approach 1:
The liquid supply path is segmented into a first path for blow molding and a second path for headspace formation. This allows the liquid blow molding process to continue providing cost advantages while the separated second path enables precise headspace formation without air contamination, resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The system uses pressure detection to monitor the liquid supply path and controls the opening-closing body to open or close the liquid supply port based on pressure changes. This feedback mechanism ensures that liquid is supplied during blow molding and then discharged for headspace formation at the appropriate times, maintaining both cost efficiency and precision.
3Reliability
If the discharge port is positioned below the liquid supply port, then air entrainment in the supply path is reduced, but the device complexity increases due to the need for an opening-closing body and dual supply paths
Solution Approach 1:
The blow nozzle merges multiple functions into a single component: it serves as both the liquid supply port for blow molding and the discharge port for headspace formation. The opening-closing body is integrated into the blow nozzle structure, allowing it to control flow in both paths without requiring separate valves or actuators, thereby reducing device complexity while maintaining reliability.
Solution Approach 2:
The blow nozzle is designed as a multi-functional component that performs both liquid supply during blow molding and liquid discharge for headspace formation. The opening-closing body provides universal control over liquid flow in both directions, eliminating the need for separate control mechanisms and reducing overall device complexity while ensuring molding condition stability.
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 enables the precise manufacturing of liquid containers with predetermined capacity and shape at low cost, improving stability and reducing air entrainment, thus enhancing molding conditions and moldability.
Implementation Method 1
supplying pressurized liquid into the preform through the liquid supply port by the pressurized liquid supply source
Implementation Method 2
the liquid which is pressurized to a pressurized pressure by using a pressurizing unit, such as a pump, is supplied into the preform
Implementation Method 3
pressurized gas is supplied from the pressurized gas supply source into the liquid container through the gas supply port to thereby assist the discharge
Data Source
AI summary
A liquid container manufacturing method includes: a liquid blow molding step of molding a preform into a liquid container; and a headspace formation step of forming a headspace, by discharging, in a state in which a liquid supply path is closed, a liquid out of the liquid container through a discharge port, the discharge accomplished by drawing-in by a liquid drawing source. In the headspace formation step, a pressurized gas is supplied from a pressurized gas supply source into the liquid container through a gas supply port to thereby assist the discharge, by the drawing-in, of the liquid out of the liquid container through the discharge port, and, when a pressure in a discharge path has increased to a set value, the supply of the pressurized gas by the pressurized gas supply source is stopped.