Thermoplastic Container Preform Connection Element Insertion
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Solution Overview
Problem
Existing methods for producing containers from thermoplastic material with connection elements passing through the wall face challenges such as material damage, complex processes, and high costs due to the need for precise punching and material displacement, which compromise the barrier layers and increase production complexity.
Innovation Solution
A method involving the creation of an opening in the still warm-plastic preform from the inside, allowing a connection element to be inserted and connected positively or materially, using a mandrel and sizing sleeve to ensure reliable sealing with larger tolerances and reduced material displacement, eliminating the need for a large punching unit and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a connection element is pushed through the container wall using a punching unit from the outside, then the connection element can be installed in the container, but the barrier layers are damaged and the process becomes complex requiring precise punching and material displacement
Solution Approach 1:
Instead of pushing the connection element through the container wall from the outside using a punching unit, the invention inverts the approach by introducing the connection element from the inside of the container. The connection element is inserted through an opening in the preform from the molding recess side, allowing it to penetrate the wall from the interior rather than from the exterior, thereby avoiding damage to the barrier layers while simplifying the installation process
2Ease of manufacture
If a punching unit is used to create openings in the container wall, then connection elements can be installed, but the process complexity and costs increase due to the need for precise punching and material displacement
Solution Approach 1:
The invention extracts and eliminates the need for a complex punching unit by introducing the connection element from the inside of the container. Instead of using an external punching device to create openings and displace material, the connection element is inserted through pre-formed openings in the preform from the molding recess side, where the material is displaced inward rather than outward, thereby removing the requirement for a large and complex punching unit
3Manufacturing precision
If the connection element is inserted from the inside through an opening in the preform, then the barrier layers are protected and the process is simplified, but the opening must be created precisely in the warm-plastic preform
Solution Approach 1:
The invention applies preliminary action by creating the opening in the preform before the final molding process. The opening is formed in the warm-plastic preform while it is still in the molding tool, allowing for precise positioning and control of the opening's location and dimensions. This preliminary creation of the opening ensures that when the connection element is inserted from the inside, it can be accurately positioned without requiring complex real-time adjustments, thereby maintaining barrier layer integrity while achieving precise opening placement
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 method ensures reliable sealing and reduces production complexity by allowing larger tolerances and eliminating material displacement issues, resulting in cost-effective and efficient production of containers with connection elements that maintain the integrity of the barrier layers.
Implementation Method 1
molding and final shaping of the preform within the molding tool using differential pressure
Implementation Method 2
the at least temporarily closed molding recess formed by the molding tool is subjected to gas pressure
Implementation Method 3
the cavities of the molding tool are evacuated
Implementation Method 4
the connection element enters into a material bond with the container wall
Implementation Method 5
provision is made for the connection element to be preheated before insertion into the opening, for example by means of an infrared heating device
Implementation Method 6
Plate-shaped or shell-shaped preforms of plasticized thermoplastic material according to this invention can be made available by extruding web-shaped, shell-shaped or tube-shaped preforms
Data Source
AI summary
The invention relates to a method for producing a container from thermoplastic material having a connection element (5) passing through the wall thereof. The method comprises making available at least one plate-shaped or shell-shaped or tube-shaped preform (3) made of plasticized thermoplastic material, introducing the preform (3) into a multipart molding tool (1) having cavities defining at least one molding recess, molding and final shaping of the preform (3) within the molding tool (1) using differential pressure, piercing of the still warm-plastic preform (3) from the tool side by means of a mandrel (9) in order to produce an opening (6) in the preform (3), insertion from the molding recess side of a connection element (5) into the opening (6) produced by the mandrel (9), and connection of the connection element (5) to the preform (3).