Opaque Plastic Container Forming With Heated Mould Cooling
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Solution Overview
Problem
Existing methods for forming opaque containers, such as painting transparent containers or using 'Heat & Cool' processes, are inefficient and costly, with potential for aesthetic damage and high equipment complexity.
Innovation Solution
A method involving a heated mould with internal surface discontinuities to shape and blow a preform, followed by a gaseous stream cooling to fix opacification, without external cooling elements, ensuring stable opacification and reduced cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If painting transparent containers to make them opaque, then opacity is achieved, but production time increases and paint may become scratched or detached
Solution Approach 1:
The patent applies preliminary action by creating the opaque finish on the container surface during the blowing process itself, before the container leaves the mold. The mold surface is pre-treated with an opaque coating that transfers to the container during forming, eliminating the need for subsequent painting operations and ensuring the opacity is integrated into the container structure rather than applied as a separate layer.
Solution Approach 2:
The patent replaces the mechanical painting process with a thermal transfer process. The opaque finish is transferred from the mold surface to the container through heat and pressure during the blowing operation, substituting the need for separate painting equipment and operations. This integration of the finishing process into the forming process reduces both time and equipment requirements.
2Illumination intensity
If using Heat & Cool process with heating and cooling liquids, then opaque effect is obtained, but equipment costs and complexity increase
Solution Approach 1:
The patent extracts the cooling function from the complex Heat & Cool process, eliminating the need for heating liquids and complex temperature control systems. Only a cooling system is retained, which is applied after the blowing process to set the opaque finish. This simplification removes the need for heating equipment while maintaining the essential function of setting the container shape and finish.
Solution Approach 2:
The mold surface serves dual purposes: it provides the opaque finish through its surface treatment and simultaneously acts as the forming surface for the container. The cooling function is provided by a simple cooling system that circulates coolant through the mold, allowing the mold itself to perform the cooling function without requiring separate heating and cooling equipment.
3Illumination intensity
If using Heat & Cool process, then opaque effect is obtained, but production costs increase
Solution Approach 1:
The patent uses a relatively simple and inexpensive cooling system instead of the costly Heat & Cool process with expensive heating and cooling liquids. The cooling medium can be a simple water-based coolant that circulates through the mold, significantly reducing material costs compared to specialized heating and cooling fluids required by the Heat & Cool process.
Solution Approach 2:
The patent merges the forming and finishing operations into a single integrated process. The opaque finish is applied during the blowing operation itself through contact with the pre-treated mold surface, combining what would otherwise be separate processes. This integration eliminates the need for additional heating equipment and complex temperature control systems, reducing both capital equipment costs and operational expenses.
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
Reduces production cycle times, lowers equipment complexity, and decreases costs while maintaining consistent opacification, enhancing production efficiency.
Implementation Method 1
heating the mould 2 at least at the beginning of the forming process
Implementation Method 2
cooling the first container 100 by introducing a gaseous stream into the container 100
Data Source
AI summary
Method for forming a container, includes the steps of: —positioning a first preform made of plastic material in a forming chamber of the mould; —counter-shaping the first preform to the mould obtaining the first container; the step of counter-shaping the first preform includes the step of performing a blowing of the first preform placed inside the forming chamber; at least a portion of a surface of the mould which delimits the forming chamber being shaped to obtain an opacification of at least a portion of the first container; —cooling the first container by introducing a gaseous stream into the container for fixing the opacification on the first container; —removing the first container from the mould; and —keeping the mould at a higher temperature than room temperature at least from the step of performing the blowing to that of removing the first container.