Nested blow molded liner and overpack and methods of making same
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Solution Overview
Problem
Current methods for manufacturing liner-based systems are not efficient, particularly in minimizing particle and bubble contamination in ultrapure liquids used in microelectronic manufacturing, leading to product failure and reduced quality.
Innovation Solution
A liner-based system is created using a nested blow-molding process where the liner and overpack are made from different materials with varying melting points, allowing the liner to collapse away from the overpack for dispensing, and featuring surface controls and coatings for integrity and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current manufacturing methods are used for liner-based systems, then production can be maintained, but particle and bubble contamination in ultrapure liquids increases leading to product failure
Solution Approach 1:
The patent applies nested blow-molding where the liner preform is placed inside the overpack preform before simultaneous molding. This nesting approach allows both components to be formed in a single integrated process, eliminating separate assembly steps that could introduce contamination. The liner and overpack are created as a unified system, reducing handling and potential particle introduction.
Solution Approach 2:
The manufacturing process merges the formation of the liner and overpack into a single blow-molding operation. By combining these two separate manufacturing steps into one simultaneous process, the patent eliminates intermediate handling, transfer operations, and assembly steps that could generate particles and bubbles, thereby improving product quality and reducing contamination.
2Ease of manufacture
If the liner is made from the same material as the overpack, then manufacturing is simpler, but the liner cannot collapse away from the overpack for efficient dispensing
Solution Approach 1:
The patent applies local quality by using different materials for the liner and overpack based on their specific functional requirements. The liner uses a material with a lower melting point suitable for collapse during dispensing, while the overpack uses a material with higher structural integrity. This localized material differentiation optimizes both manufacturing and dispensing operations.
Solution Approach 2:
The patent implements dynamics by designing the liner to transition from a rigid state during storage to a collapsible state during dispensing. The liner material is specifically selected to allow controlled collapse when exposed to heat or pressure, enabling efficient product evacuation. This dynamic behavior optimizes the dispensing operation while maintaining manufacturing simplicity through the integrated molding process.
3Productivity
If the liner collapses uniformly without control, then dispensing may be incomplete, but adding control features increases manufacturing complexity
Solution Approach 1:
The patent applies segmentation by dividing the liner surface into multiple discrete panels rather than attempting uniform collapse. These segmented panels are formed by strategic placement of parting lines and ejector pins during blow-molding. The segmentation allows controlled collapse progression across different zones of the liner, ensuring complete product evacuation while maintaining relatively simple manufacturing through the integrated molding process.
Solution Approach 2:
The patent implements preliminary action by pre-forming the liner with specific surface features, panels, and geometric characteristics during the initial blow-molding process. These pre-formed features are designed to guide the collapse progression and ensure complete dispensing. By preparing the liner structure in advance during manufacturing rather than adding complexity during operation, the patent achieves complete dispensing while minimizing manufacturing 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 approach enables efficient dispensing of ultrapure liquids at low pressures, reduces particle contamination, and maintains the integrity of the contents, enhancing the reliability and quality of microelectronic manufacturing processes.
Implementation Method 1
heating the nested preforms to a first temperature; heating the nested preforms to a second temperature
Implementation Method 2
blow molding the heated nested preforms at the same time
Data Source
AI summary
The present disclosure relates to an integrated liner-based system having an overpack and a liner provided within the overpack, the liner comprising a mouth and a liner wall forming an interior cavity of the liner and having a thickness such that the liner is substantially self-supporting in an expanded state, but is collapsible at a pressure of less than about 20 psi. The liner and overpack may be made by blow molding the liner and the overpack at the same time using nested preforms.