Plastic vessel with integrated metal element, and method producing the same
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Solution Overview
Problem
Plastic vessels with embedded metal elements, such as magnets, often suffer from cracking due to thermal expansion differences during injection molding, leading to short service life and inadequate protection from external influences, and magnetic properties can be impaired during manufacturing.
Innovation Solution
A plastic vessel designed in two pieces with a recessed base that houses the metal element, thermoplastically bonded under pressure after both components have fully solidified, ensuring no cracks form and maintaining magnetic properties, using a method that allows for mass production and decorative integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal element is embedded in the plastic vessel during injection molding, then the vessel achieves non-slip positioning capability, but cracks form in the plastic due to thermal expansion differences
Solution Approach 1:
The vessel is divided into two separate components: a plastic vessel body and a metal element. The metal element is inserted into a recess in the base of the vessel after the plastic has solidified, rather than being embedded during injection molding. This segmentation prevents thermal expansion conflicts while maintaining the non-slip positioning function through magnetic attraction between the metal element and the vessel.
Solution Approach 2:
The recess for accommodating the metal element is pre-formed in the plastic vessel base during injection molding. The metal element is then inserted into this pre-prepared recess after the plastic has solidified. This preliminary preparation allows the metal element to be positioned correctly without being subjected to the high temperatures and pressures of injection molding, preventing crack formation while ensuring proper positioning.
2Strength
If the metal element is completely surrounded by cooling and solidifying plastic, then the vessel structure is strengthened, but the magnetic remanence of the magnet is impaired
Solution Approach 1:
The recess for the metal element is pre-formed in the plastic vessel base during injection molding. The metal element is then inserted into this pre-prepared recess after the plastic has solidified and cooled to room temperature. This ensures the plastic provides structural strength while the metal element retains its magnetic properties, as it is not exposed to high temperatures during molding.
Solution Approach 2:
The temperature parameter is controlled by inserting the metal element after the plastic has cooled to room temperature, rather than during the high-temperature injection molding process. This parameter change preserves the magnetic remanence of the metal element while still achieving a strong structural bond between the plastic vessel and the metal element through the recess design.
3Ease of manufacture
If the vessel is made as a single piece during injection molding, then manufacturing is simplified, but aesthetic requirements cannot be met due to crack formations
Solution Approach 1:
The vessel is manufactured as two separate components: the plastic vessel body and the metal element. The plastic vessel is injection molded with a pre-formed recess in the base, and the metal element is subsequently inserted into this recess. This segmentation eliminates crack formations that would occur with embedding, meeting aesthetic requirements while maintaining manufacturing efficiency through the modular assembly process.
4Productivity
If the metal element is embedded during injection molding, then production time is reduced, but the service life of the vessel becomes unacceptably short
Solution Approach 1:
The recess for the metal element is pre-formed during injection molding of the plastic vessel base. The metal element is then quickly inserted into this pre-prepared recess after the plastic has solidified. This preliminary preparation significantly reduces assembly time compared to other methods, while the resulting vessel has an extended service life because the metal element is protected from external influences and the plastic is free from stress-induced cracks.
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 provides a durable, aesthetically pleasing plastic vessel with a long service life, suitable for use in vehicles and as a non-slip container, while maintaining magnetic properties and allowing for easy cleaning, including the use of RFID tags without compromising the vessel's integrity.
Implementation Method 1
the cover (2) and the vessel element (1) being thermoplastically bonded together under pressure by shrinkage of the hot plastic
Implementation Method 2
a magnetic metal element for use in conjunction with a means of transport and in particular for use in a vehicle
Data Source
Figure 1a~1f
Figure 2a~2d
Figure 3a~3d
AI summary
The invention relates to a plastic container that accommodates a metal element (3) in its base (10), the plastic container comprising a container element (1) and a cover (2), so that the plastic container is designed in two pieces, and the base ( 10) the vessel element (1) has a recess (12) which is covered by a cover (2) in such a way that a central closed area (14) of the recess (12) is provided, which accommodates the metal element (3), and wherein the vessel (1) and the cover (2) are thermoplastically and pressure bonded together. The vessel element (1) and the cover (2) are in particular made of copolyester or polycarbonate, and the plastic vessel is in particular a drinking glass, and the metal element (3) is in particular a neodymium magnet with a copper-nickel coating. The invention also relates to a method for producing a plastic container, taking into account the thermoplastic properties of the plastic used, and the use of the container in conjunction with a suitable means of transport and/or in a vehicle of any type and/or for the handling of people with restricted motor skills and /or perception and/or attention and/or as a decorative element.