Plastic Transport Case Corner Cladding Design
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Solution Overview
Problem
Existing methods for producing plastic transport containers, such as bottle crates, are limited in design options when combining two plastics, as they require a semi-finished product to be arranged in relation to an injection mold and involve complex processes for delimiting plastic surfaces, leading to connection issues and restricted design possibilities.
Innovation Solution
An adjustable mold element is used to create an additional mold cavity within the injection mold, allowing the second plastic cladding layer to be applied without transferring the base shell, eliminating the need for severe cooling and connection problems, and enabling a covering layer to extend over corners and edges for enhanced design and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a semi-finished product is arranged in relation to an injection mold to inject the second plastic, then the second plastic can be applied to the container, but the process becomes complex and design options are limited
Solution Approach 1:
The patent combines the first and second injection molding processes into a single integrated mold system. The mold contains both a first mold cavity for the base shell and a second mold cavity for the covering layer, allowing both plastics to be molded in one continuous operation without transferring the semi-finished product between different molds. This merging of processes eliminates the complexity of arranging and repositioning semi-finished products while maintaining full design flexibility for both plastic components.
2Manufacturing precision
If a circumferential sealing strip or sealing groove is used to delimit the second plastic, then the liquid melt is prevented from spreading, but the design freedom is restricted
Solution Approach 1:
The patent employs separate mold cavities with independent control for the first and second plastics. Each cavity can be designed with specific local features such as sealing strips or grooves only where needed for that particular plastic component. This allows precise delimitation of plastic surfaces while maintaining design freedom, as each cavity can be optimized independently without being constrained by a single circumferential sealing structure that would limit overall design possibilities.
3Adaptability or versatility
If the covering layer is extended over corners and edges, then design freedom and mechanical strength are improved, but the connection between layers becomes more challenging
Solution Approach 1:
The patent incorporates preliminary connection features directly into the mold cavity design before the injection molding process begins. The mold includes integrated connection elements such as recesses, protrusions, or interlocking structures that are formed simultaneously with the base shell and covering layer. This preliminary action ensures reliable connection between the layers from the outset, allowing the covering layer to extend freely over corners and edges without compromising connection reliability, as the connection is already established through the molded-in features.
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 allows for increased design freedom and improved mechanical strength, abrasion resistance, and noise reduction, while also providing a smooth surface and pleasant handling properties, by eliminating the need for separate injection molds and enhancing the connection between the base shell and the enveloping layer.
Implementation Method 1
The invention relates to a transport crate made of plastic injection molding
Implementation Method 2
liquid plastic for the covering layer is injected, as a result of which the two adjacent layers of material are firmly connected
Implementation Method 3
The adjustable shaped elements can be adjusted from a first position, in which the mold cavity for the base shell is delimited, to a second position, in which an additional mold cavity for the covering layer is formed
Implementation Method 4
The adjustable shaped elements can be spaced from the solidified base shell by a distance corresponding to a desired wall thickness of the covering layer
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The transport case has a cladding layer (16) partially covering a corner region (5) between two sidewalls (4) of a base shell (15) and/or one of two sidewalls and a base (3) and/or one of two sidewalls and an edge (6) of the base shell in a single-piece manner, where the edge is limited by the corner region. The cladding layer extends over a section of one of two sidewalls and an upper edge (7) of the base shell in a single-piece manner, where the base shell and the cladding layer are made of plastic materials, respectively. Independent claims are also included for the following: (1) a method for manufacturing a transport case (2) an injection molding tool for manufacturing a transport case.