Nested Blow-Molded Liner Overpack for Low-Contamination Dispensing
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Solution Overview
Problem
Current manufacturing methods for 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 nested blow-molding process is used to create liner-based systems where the liner and overpack are made from different materials with varying melting points, featuring surface features and coatings to control collapse and prevent contamination, and include air channels for even gas flow during dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional separate manufacturing processes are used for liner and overpack, then material selection flexibility is improved, but manufacturing efficiency and productivity deteriorate
Solution Approach 1:
The patent combines the manufacturing of the liner and overpack into a single nested blow-molding process. The liner preform is inserted into the overpack preform, and both are molded simultaneously in one operation, eliminating the need for separate manufacturing steps while maintaining the ability to use different materials for each component.
Solution Approach 2:
The patent employs nesting by placing the liner preform inside the overpack preform before the blow-molding process. This nested configuration allows both components to be formed in a single manufacturing cycle, improving productivity while preserving material selection flexibility since each preform can be made from different materials.
2Speed
If high pressure is used for dispensing, then dispensing speed is improved, but particle contamination and product failure increase
Solution Approach 1:
The patent uses a collapsible liner made from flexible material that can be compressed to dispense contents. The liner's flexibility allows it to collapse inward as liquid is dispensed, creating a gentle pushing action that moves liquid without requiring high pressure, thereby avoiding particle generation and contamination.
Solution Approach 2:
The patent changes the pressure parameter from high to low by utilizing the collapsible nature of the liner. As the liner collapses, it gradually pushes liquid out through the dispensing opening, maintaining low pressure throughout the dispensing process while still achieving effective liquid flow.
3Ease of manufacture
If liner and overpack are made from the same material, then manufacturing simplicity is improved, but functional versatility and protection capabilities deteriorate
Solution Approach 1:
The patent uses composite material construction where the liner and overpack are made from different materials selected for their specific functional requirements. The liner can be made from a material optimized for chemical compatibility and flexibility, while the overpack uses a material providing structural strength and environmental protection, creating a functionally versatile system.
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 enhances the efficiency and integrity of liner-based systems, reducing particle and bubble contamination, ensuring higher product quality and reliability in microelectronic manufacturing processes.
Implementation Method 1
heating the liner preform to a first temperature; heating the nested liner and overpack preforms
Implementation Method 2
the liner and overpack being comprised of different materials having different melting points
Implementation Method 3
air channels during the blow mold process that permit gas introduced during pressure dispense or pressure assisted pump dispense to flow more evenly throughout the annular space between the overpack and liner
Implementation Method 4
The liner may be configured to collapse away from an interior wall of the overpack upon the introduction of a gas or liquid into an annular space between the liner and the overpack
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.