Multi-layer Injection Molded Container with Biased Barrier Layer
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Solution Overview
Problem
Injection molded containers made of polymers like polyethylene, polyethylene terephthalate, and polypropylene are permeable to oxygen and gases, leading to substance degradation, and existing barrier layers in these containers are difficult to precisely control during coinjection molding and are susceptible to damage.
Innovation Solution
A coinjection molded multi-layer container with an inner layer, an outer layer, and a barrier layer, where the barrier layer is biased towards either the inside or outside surface, and an injection molding control system using a camera and controller to monitor and control the position of the barrier layer during molding, ensuring precise placement and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a barrier layer is added to reduce gas permeation, then gas permeation resistance is improved, but manufacturing precision deteriorates due to difficulty in controlling barrier layer position during coinjection molding
Solution Approach 1:
The patent employs real-time feedback control during the coinjection molding process. Sensors monitor the position of the barrier layer as it is being injected, and the system automatically adjusts injection parameters to maintain the barrier layer at the desired position, thereby achieving both effective gas permeation resistance and precise manufacturing control
Solution Approach 2:
The patent replaces traditional mechanical positioning methods with a control system that uses real-time monitoring and automated adjustment. Instead of relying solely on mechanical fixtures and manual positioning, the system uses feedback control to dynamically manage barrier layer placement, improving both precision and consistency
2Object-affected harmful factors
If a barrier layer is added to prevent gas permeation, then gas permeation resistance is improved, but reliability deteriorates due to susceptibility of the barrier layer to damage after container formation
Solution Approach 1:
The patent incorporates protective measures during the molding process itself. The barrier layer is designed with appropriate thickness and is positioned within a protective structure of the multi-layer container. Additionally, the molding process parameters are optimized to prevent damage before the container is even formed, cushioning the barrier layer against potential stresses and damages
Solution Approach 2:
The patent creates a composite multi-layer structure where the barrier layer is combined with other polymer layers that provide mechanical strength and protection. This composite structure allows the barrier layer to perform its gas permeation resistance function while being protected by the surrounding layers, thereby improving overall reliability without sacrificing barrier effectiveness
3Object-affected harmful factors
If the barrier layer is made thicker to improve gas permeation resistance, then gas permeation resistance is improved, but device complexity increases due to different layer thicknesses and biased positioning
Solution Approach 1:
The patent applies local quality by positioning the barrier layer strategically within the multi-layer structure and varying its thickness only where necessary for gas permeation resistance. The barrier layer is biased toward one surface (inner or outer) rather than being uniformly distributed, creating different local thicknesses that optimize both gas barrier performance and structural efficiency without unnecessarily increasing overall 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
The solution effectively reduces gas permeation by precisely controlling the barrier layer's position and thickness, enhancing the container's ability to prevent oxygen and gas permeation while maintaining structural integrity.
Implementation Method 1
The barrier layer is located between the inner layer and the outer layer and includes a second polymeric material less permeable to gas than the first polymeric material
Data Source
AI summary
A coinjection molded multi-layer container includes an inner layer, an outer layer, and a barrier layer. The inner layer includes a first polymeric material and forms an inside surface of the container. The outer layer includes the first polymeric material and forms an outside surface of the container. The barrier layer is located between the inner layer and the outer layer and includes a second polymeric material less permeable to gas than the first polymeric material. The barrier layer is biased toward the inside surface or the outside surface such that the inner layer and the outer layer have different thicknesses.