Monolithic Blowing for Decorative Candle Inner Patterns
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Solution Overview
Problem
The conventional electronic candle manufacturing process is complex, time-consuming, and has a poor yield rate due to its two-step process involving injection molding and subsequent surface processing like etching and electroplating, making it less competitive.
Innovation Solution
A decorative candle with a monolithically formed inner pattern using a light-transmittable plastic material, where the candle body and patterns are created through blowing, and a light-emitting device is integrated inside for efficient and streamlined production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding followed by etching/transfer printing/electroplating is used to manufacture electronic candles, then decorative patterns can be achieved on the inner surface, but the manufacturing process becomes complex and time-consuming with poor yield rate
Solution Approach 1:
The patent merges the pattern formation and candle body manufacturing into a single blowing process. The patterned insert is placed in the mold cavity before blowing, allowing the pattern to be directly imprinted on the inner surface of the candle body during the forming process itself, eliminating the need for separate etching, transfer printing, or electroplating steps.
Solution Approach 2:
The patent uses a pre-formed patterned insert that is placed into the mold cavity before the blowing process. This insert already contains the desired pattern, which is then transferred to the candle body during forming. This preliminary preparation of the pattern on the insert eliminates the need for complex post-processing steps.
2Manufacturing precision
If injection molding followed by etching/transfer printing/electroplating is used to manufacture electronic candles, then decorative patterns can be achieved on the inner surface, but production time increases and yield rate decreases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single blowing process. The patterned insert is placed in the mold, and the blowing process simultaneously forms the candle body and imprints the pattern on the inner surface in one operation, dramatically reducing production time and increasing yield rate compared to sequential processes.
Solution Approach 2:
By pre-forming the pattern on the insert before the blowing process, the patent eliminates time-consuming post-processing steps. The pattern is already prepared and will be transferred during the forming process itself, streamlining production and improving efficiency.
3Manufacturing precision
If conventional two-step manufacturing process is used for electronic candles, then decorative patterns can be created, but the process is prone to poor yield rate
Solution Approach 1:
The patent merges pattern formation and body forming into a single blowing process using a patterned insert. This integrated approach eliminates the multiple handling and transfer steps between separate processes that cause defects and reduce yield rate, while maintaining high pattern quality.
Solution Approach 2:
The pattern is pre-formed on the insert which is then placed in the mold before blowing. This preliminary preparation ensures the pattern is stable and will be accurately transferred during the forming process without the defects associated with post-processing operations like etching or electroplating.
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 approach simplifies the manufacturing process, enhances yield rates, and reduces complexity, resulting in a more competitive and efficient production method for electronic candles with improved decorative and ambient effects.
Implementation Method 1
a candle main body with inner pattern, made of light-transmittable plastic material
Implementation Method 2
the candle main body and the patterns being monolithically formed by blowing
Data Source
AI summary
A decorative candle with inner pattern includes: a candle main body with inner pattern, and a light-emitting device. The candle main body is made of light-transmittable plastic material, has at least an inner surface and an outer surface. The outer surface is smooth, and the inner surface has a plurality of predefined patterns. The candle main body and the patterns are monolithically formed by blowing. The light-emitting device is disposed inside the candle main body, has at least a light source and an electrical box for providing power to the light source. As such, in the decorative candle with pattern of the present invention, the patterns on the inner surface and the candle main body are monolithically manufactured by blowing, and thus the problems associated with the conventional two-process manufacturing are eliminated.