Composite Preform Bottom Portion Bonding for Light Shielding

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Solution Overview

Problem

Conventional biaxial stretch blow molding methods struggle to impart various functions and characteristics, such as light shielding properties, to the bottom portion of composite containers, and face challenges with bubble generation and breakage during the manufacturing process.

Innovation Solution

A composite preform is manufactured using a heat shrinkable plastic member with a thermocompression bonding method, where the plastic member is bonded to the preform along the shape of the bottom portion, and a twisting step is included to enhance close contactability and prevent breakage during blow molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a heat shrinkable plastic member is used to cover the bottom portion of the container main body, then the light shielding properties and appearance are improved, but bubble generation occurs during blow molding and the close contactability is insufficient

Engineering Contradiction:

Improvelight shielding propertiesVSAvoidbubble generation

Core Design Contradiction:

Illumination intensityVSObject-generated harmful factors

Solution Approach 1:

The plastic member is thermocompression bonded to the preform before blow molding, creating a secure attachment in advance. This preliminary bonding action prevents bubble generation during the subsequent blow molding process and ensures the plastic member maintains close contactability with the container main body while providing the desired light shielding properties.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If the plastic member is thermocompression bonded to the preform, then the close contactability is improved, but the bonding portion may break during blow molding

Engineering Contradiction:

Improveclose contactabilityVSAvoidbonding integrity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The thermocompression bonding is performed under controlled temperature and pressure parameters to create a strong bond. The bonding temperature is set to a range that softens the plastic member enough for bonding while maintaining structural integrity, and the bonding pressure is optimized to ensure strong adhesion without creating weak points that would break during blow molding.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The thermocompression bonding creates a pre-strengthened connection between the plastic member and preform before the blow molding process. This beforehand bonding acts as a cushioning effect, distributing the stresses during blow molding and preventing breakage at the bonding portion while maintaining close contactability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Area of stationary object

If the plastic member is made longer to ensure complete coverage of the bottom portion, then the coverage is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvecoverage areaVSAvoidmanufacturing complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The plastic member is prepared with a predetermined length extension before insertion into the preform. This preliminary preparation ensures that when the plastic member is positioned and thermocompression bonded, it extends sufficiently to completely cover the bottom portion of the container main body. The predetermined length is calculated in advance to achieve complete coverage without requiring complex adjustments during manufacturing.

Inventive Principle:

Principle #10Preliminary action

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 ensures complete coverage of the bottom portion, prevents bubble generation, and maintains the integrity of the thermocompression bonding, resulting in a composite container with improved appearance and functional properties.

Implementation Method 1

having the plastic member undergo thermal shrinkage by heating the preform and the plastic member

Methodology Applied

Scientific EffectThermal shrinkage: Thermal Contraction

Implementation Method 2

bonding the margin of the plastic member by thermocompression

Methodology Applied

Scientific EffectThermocompression bonding:

Data Source

PatentUS11213992B2Composite preform, method for manufacturing same, composite container, method for manufacturing said composite container, and heat shrinkable plastic member

Publication Date: 2022.01.04 DAI NIPPON PRINTING CO LTD

AI summary

A method for manufacturing a composite preform is provided, including preparing a preform that is formed from a plastic material, preparing a tubular heat shrinkable plastic member that is longer than the preform and has a margin for thermocompression bonding at one end, inserting the preform into the plastic member having the plastic member undergo thermal shrinkage by heating the preform and the plastic member, and bonding the margin of the plastic member by thermocompression.