Blow-Molded PET Container Base With Folded Sidewall
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Solution Overview
Problem
Current PET containers, despite being lightweight and recyclable, lack optimal adjustment to varying internal pressures and structural integrity, particularly in terms of weight reduction and increased strength.
Innovation Solution
A blow-molded container design featuring a base portion with a fold and diaphragm that absorbs internal vacuum, maintaining shape under top load, and includes vacuum ribs for reinforcement, allowing the container to adjust to pressure changes and resist deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical processing and thermal processing are used to increase PET polymer crystallinity, then the container's strength and structural integrity are improved, but the container weight increases and material thickness must be maintained
Solution Approach 1:
The patent changes the physical-chemical parameters of the PET material through controlled crystallization processes, transforming the polymer from amorphous to semi-crystalline form. This parameter change increases the material's strength and stiffness, allowing the container to maintain structural integrity with reduced wall thickness, thereby reducing overall weight while improving strength
Solution Approach 2:
The patent creates a composite structure within the container wall by forming a crystalline phase distributed within the amorphous PET matrix. This semi-crystalline composite material combines the flexibility of amorphous regions with the strength of crystalline regions, achieving improved mechanical properties without proportionally increasing weight
2Reliability
If heat setting is used to produce PET bottles with higher crystallinity (25%-35%), then the container's resistance to deformation under hot-fill conditions is improved, but the manufacturing process complexity and time increase
Solution Approach 1:
The patent applies heat setting during the blow-molding process itself, performing the crystallization action preliminarily before the container enters service. The container is heated to 100°C-150°C and held for 2-10 seconds during manufacturing, pre-establishing the crystalline structure that will provide reliability during subsequent hot-fill operations, thereby simplifying the overall manufacturing process
Solution Approach 2:
The patent merges the heat setting operation with the blow-molding manufacturing process. By integrating the thermal treatment step into the existing manufacturing sequence, the patent eliminates the need for separate post-manufacturing heat treatment equipment and processes, reducing manufacturing complexity while achieving the desired crystallinity for hot-fill reliability
3Weight of moving object
If the container wall thickness is reduced to decrease weight, then the container's adaptability to varying internal pressures is improved, but the structural strength and resistance to deformation decrease
Solution Approach 1:
The patent changes the material parameters by increasing the degree of crystallinity in the PET container wall. This parameter change fundamentally alters the material's mechanical properties, providing higher strength and stiffness per unit thickness. Consequently, the container can be made lighter with reduced wall thickness while maintaining adequate structural strength and pressure resistance
Solution Approach 2:
The patent applies local quality enhancement through selective crystallization in different regions of the container wall. The crystalline structure is optimized in areas subject to higher stresses, providing localized strength enhancement that allows overall weight reduction while maintaining structural integrity in critical regions
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 container effectively maintains its shape under varying internal pressures and top loads, providing improved structural integrity and reduced weight without compromising strength, with enhanced manufacturing consistency and reduced material thickness.
Implementation Method 1
The base portion that effectively absorbs internal vacuum while maintaining basic shape
Implementation Method 2
resists deforming under top load
Data Source
Figure 1A
Figure 1B~1D
Figure 2A~3
AI summary
A blow-molded container including a finish and a base portion. The finish defines an opening at a first end of the container that provides access to an internal volume defined by the container. The base portion is at a second end of the container opposite to the first end. The base portion includes a fold proximate to a sidewall of the container.