Multilayer Thermoplastic Container with Underlying Colorant
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Solution Overview
Problem
Forming multilayer blow molded containers with colorants in an underlying layer is technically challenging due to the complexity of controlling extrusion of multiple layers, and existing methods are expensive and inefficient.
Innovation Solution
A container formed from a one-piece multilayer thermoplastic substrate where the underlying layer contains a visible colorant, achieved by forming a planar web of thermoplastic material into a conduit and then blow molding it into a container with a common substrate for both the closed end and container wall, using a forming guide and conformer to create a seamless structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multilayer extrusion blow molding is used to create containers with colorants in underlying layers, then the visual appearance and functionality are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The container wall is divided into distinct layers: an outer layer and an underlying layer containing colorants. This segmentation allows each layer to be optimized independently - the outer layer for clarity and protection, the underlying layer for visual effect - while simplifying the extrusion process compared to fully multilayer colorant integration.
Solution Approach 2:
The colorants are incorporated into the underlying layer during the extrusion process before the container is formed. This preliminary action of adding colorants to the extruded material simplifies manufacturing by avoiding post-production coloring methods while achieving the desired visual appearance.
2Ease of manufacture
If multiple layers of material are extruded to form a parison with colorants, then the visual appearance is enhanced, but the manufacturing cost and process complexity increase
Solution Approach 1:
The outer layer and underlying layer with colorants are extruded as a combined multilayer structure in a single process operation. This merging of layers during extrusion eliminates the need for separate coloring operations and reduces manufacturing steps while maintaining the enhanced visual appearance.
Solution Approach 2:
The extrusion process parameters are optimized to control the thickness and positioning of each layer, with the underlying layer containing colorants positioned at specific depths. By controlling extrusion parameters rather than adding complex post-processing steps, manufacturing efficiency is maintained while achieving the desired visual effect.
3Illumination intensity
If colorants are intensifyed in the underlying layer with a clear outer layer, then the visual effect is enhanced, but the difficulty of controlling material extrusion increases
Solution Approach 1:
The container wall has different properties at different locations: the outer layer provides clarity and protection, while the underlying layer contains concentrated colorants. This local quality differentiation allows intense color visibility where needed while maintaining manufacturing control through standardized extrusion processes for each layer.
Solution Approach 2:
The container wall is constructed as a composite structure with an outer thermoplastic layer and an underlying layer containing colorants. This composite material approach allows the colorants to be intensifyed in the underlying layer while the clear outer layer provides protection and visual clarity, with the extrusion process controlling the composite structure formation.
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 simplifies the manufacturing process, reduces costs, and allows for the easy integration of colorants in the underlying layer, resulting in a cost-effective and visually appealing multilayer container with a seamless construction.
Implementation Method 1
forming a planar web of thermoplastic material into a conduit and then blow molding it into a container
Data Source
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AI summary
A container formed of a common one-piece multilayer thermoplastic substrate. The container wall has an outer layer and an adjacent underlying layer. And the underlying layer has a colorant visible through the outer layer. The colorant in the underlying layer can be one or more pigments and or one or more dyes.