One-Piece Plastic Container with Integrated Pour Spout
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Solution Overview
Problem
The existing two-piece plastic container designs with angled spouts require significant material and manufacturing costs, and there is a need for a cost-effective, one-piece design that integrates a pourable spout feature into the container's finish.
Innovation Solution
A one-piece plastic container design featuring a spout with a terminal lip and longitudinal slot, where the spout is integrally formed with the container, reducing material usage and manufacturing complexity by eliminating the need for separate components and assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a two-piece design with an angled spout is used, then pouring functionality is improved, but material usage and manufacturing costs increase
Solution Approach 1:
The spout is integrated directly into the container body as a one-piece design, eliminating the need for separate spout components and their associated assembly processes. The molded-in spout combines the container and pouring features into a single structural unit, reducing material usage while maintaining pouring functionality.
Solution Approach 2:
The container body serves multiple functions: it holds the commodity and simultaneously provides the pouring spout feature through its integrated design. The finish structure performs both closure engagement and spout formation, reducing the need for additional components.
2Ease of operation
If a two-piece design with an angled spout is used, then pouring functionality is improved, but manufacturing complexity and cycle time increase
Solution Approach 1:
The spout and container are formed as a single integrated piece through injection molding, eliminating separate assembly operations. The molded-in spout design combines multiple manufacturing steps into one continuous process, reducing manufacturing complexity and cycle time while maintaining pouring functionality.
3Loss of substance
If a molded-in spout is used, then material usage is reduced, but structural integrity may be compromised
Solution Approach 1:
The finish structure is designed with localized thickness variations and reinforcement features specifically at the spout integration zone. The molecular orientation and crystallinity are optimized in the spout region to maintain structural integrity while using minimal material overall.
Solution Approach 2:
The injection molding process parameters are optimized to control material flow, cooling rates, and crystallization in the spout region. These parameter changes ensure proper molecular orientation and structural strength in the integrated spout while minimizing overall material usage.
Data Source
AI summary
A one-piece plastic container includes a body defining a longitudinal axis and having an upper portion, a sidewall portion and a base portion. The upper portion has a spout defining an opening into the container and a finish offset radially outwardly from the spout. A trough defines a passage into the body. The trough slopes toward the passage and defines a non-orthogonal angle relative to the longitudinal axis. According to other features, the sidewall portion is integrally formed with and extends from the upper portion to the base portion. The base portion closes off an end of the container. The finish defines a means, such as at least one thread, for attaching a closure thereon.