Polymer Container With Foamed Inner Layer and Film Outer Wall
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Solution Overview
Problem
Existing methods for forming polymeric containers are inefficient in reducing material weight and complexity, while maintaining desirable surface appearances.
Innovation Solution
A method of forming a polymeric container with a multi-layer side wall and floor, comprising a foamed inner layer and an outer film layer, where a density-reducing additive is used to create a reduced-density tube that is then trimmed and formed into containers, allowing for pre-decoration of the film sheet to reduce printing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a multi-layer structure with foamed inner layer and film outer layer is used, then material weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent combines the foaming process and multi-layer formation into a single integrated extrusion process. The multi-layer resin composition is extruded as one continuous operation, with the foaming agent decomposing in-situ to create the foamed inner layer while the outer film layer forms simultaneously, merging multiple manufacturing steps into one unified process that reduces overall complexity despite the multi-layer structure
Solution Approach 2:
The patent uses a composite resin composition consisting of multiple polymer types (first resin and second resin) with different properties. The first resin forms the foamed inner layer providing light weight, while the second resin forms the non-foamed outer film layer providing surface quality. This composite material approach allows weight reduction through foaming while maintaining a simple smooth outer surface suitable for decoration
2Adaptability or versatility
If printing is performed after container formation, then design flexibility is improved, but production time and cost increase
Solution Approach 1:
The patent applies decorative patterns directly to the film layer during the extrusion and forming process, before the container is fully formed and cooled. This preliminary decoration action allows the design to be integrated into the container structure itself, eliminating subsequent printing steps and accelerating production while maintaining design flexibility
Solution Approach 2:
The patent merges the decoration application process with the container formation process. By applying decorative patterns to the film layer while it is still in the extrusion line, the decoration step is combined with the manufacturing step, eliminating sequential operations and improving production efficiency without sacrificing design versatility
3Weight of moving object
If density-reducing additive is added to create foamed structure, then material weight is reduced, but surface smoothness may deteriorate
Solution Approach 1:
The patent applies local quality by having different resin compositions in different regions of the container wall. The inner layer contains the foaming agent for weight reduction, while the outer layer is composed of resin without foaming agent to maintain surface smoothness. This spatial differentiation of material properties allows the foamed structure to provide weight reduction locally without compromising the overall surface quality needed for decoration
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 method achieves containers with reduced material weight and complexity, while maintaining a smooth and glossy outer appearance, and allows for cost-effective and time-efficient production with the option for recyclable materials.
Implementation Method 1
Foaming or expanding the tube-shaped molten polymer blend within the interior of the film sheet to provide a reduced-density tube
Implementation Method 2
The layers are formed together during the method and may include the same or similar polymeric materials to encourage crosslinking between each layer
Implementation Method 3
The layers are formed together during the method and may include the same or similar polymeric materials to encourage crosslinking between each layer
Data Source
AI summary
A container includes a container closure and a multi-layer side wall coupled to the container closure. A method includes forming the container with the multi-layer side wall. The multi-layer sidewall includes a film layer and a foamed layer coupled to the film layer to provide the multi-layer sidewall.