Liquid Container Lid Insert Molding for Partition Rib Sealing
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Solution Overview
Problem
The existing manufacturing process for liquid containers, which involves separate injection molding of the container and lid followed by ultrasonic welding, is costly and inefficient, leading to potential leaks and unintended mixing of liquids due to incomplete bonding and transportation-related issues.
Innovation Solution
The process is improved by using insert molding, where the container and lid are molded separately and then inserted into new molds for bonding with a bonding resin, ensuring precise alignment and sealing between the partition ribs and the lid, thereby eliminating the need for ultrasonic welding and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate injection molding of container and lid followed by ultrasonic welding is used, then manufacturing process is established, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent combines the container molding and lid molding into a single integrated injection molding process. The lid is designed with projection portions that engage with partition ribs during the molding process itself, eliminating the need for separate ultrasonic welding operations. This merging of processes reduces both manufacturing cost and process complexity while maintaining secure sealing between storage tanks.
2Reliability
If separate injection molding followed by ultrasonic welding is used, then container and lid are bonded, but bonding reliability decreases due to transportation and handling
Solution Approach 1:
The patent performs the bonding action during the injection molding process itself, before the container and lid need to be transported or handled separately. The projection portions of the lid engage with the partition ribs while both components are still in the mold, and bonding resin is injected to seal the interface. This preliminary bonding action eliminates the risk of misalignment or incomplete bonding that would occur if components were separated and later reassembled.
3Reliability
If ultrasonic welding is used for bonding, then sealing is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the sealing function into the injection molding process by injecting bonding resin into the cavity formed between the lid's projection portions and the partition ribs. This eliminates the need for separate ultrasonic welding equipment and operations, reducing manufacturing cost while achieving reliable sealing that prevents liquid leakage and mixing between storage tanks.
4Productivity
If separate molding and assembly process is used, then manufacturing flexibility is maintained, but productivity decreases
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated injection molding process. Both the container and lid are molded in the same cycle, with the lid's projection portions automatically engaging with the partition ribs. Bonding resin is injected during the same cycle to seal the interface. This eliminates the need for separate molding, transportation, and assembly operations, dramatically improving productivity while reducing process complexity.
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 ensures a secure, liquid-tight seal between storage tanks, preventing leaks and unintended mixing of liquids, while reducing manufacturing costs and complexity.
Implementation Method 1
a bonding portion filled with bonding resin so as to seal between an edge end of the partition rib and the lid and between an edge end of an outer circumference of the container portion and the lid
Data Source
AI summary
A liquid container includes a container portion and a lid. The container portion includes a plurality of storage portions separated by at least one partition rib and storing liquid respectively in an isolated state. The lid bonded with the container portion so as to cover an opening region of the container portion. A plurality of project portions engaging with the partition rib so as to sandwich the partition rib from both sides of the partition rib is integrally molded with the lid. In a state in which the partition rib is engaged with the project portions, a bonding portion is filled with bonding resin so as to seal a cavity between an edge end of the partition rib and the lid and a cavity between an edge end of an outer circumference of the container portion and the lid.