Blow-Molding Preform Handle Notch Integration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for forming containers with integral handles require separate process steps, such as injection molding or snapping handles onto preformed containers, which are inefficient and lack integration during the blow-molding process.

Innovation Solution

A method involving heating a preform with an integral handle, stretching it using a multi-stage stretch rod, and inserting handle pocket wedge blocks into molds to expand and secure the handle within the container, allowing for simultaneous formation of the container and handle through blow-molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If handles are attached in a separate process step after blow-molding, then the container can be formed first and handles added later, but the manufacturing process becomes more complex and less efficient

Engineering Contradiction:

Improveease of manufactureVSAvoidproductivity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines the handle formation and container body formation into a single blow-molding process. The preform includes an integral handle structure that is formed simultaneously with the container body in one continuous operation, eliminating the need for separate handle attachment steps and thereby improving productivity while maintaining ease of manufacture through integrated tooling.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The handle structure is pre-formed as an integral part of the preform before the blow-molding process begins. The preform is designed with the handle geometry already incorporated, so that when the preform is stretched and blown into the final container shape, the handle is automatically formed in the correct position and configuration without requiring additional operations.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If handles are formed by injection molding or snapping onto preformed containers, then the container and handle can be created separately, but the process requires multiple steps and reduces manufacturing efficiency

Engineering Contradiction:

ImproveproductivityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention merges the handle formation and container body formation into a single blow-molding process. The preform includes an integral handle structure that is formed simultaneously with the container body in one continuous operation, eliminating the need for separate handle attachment steps and thereby improving productivity while maintaining ease of manufacture through integrated tooling.

Inventive Principle:

Principle #5Merging (Combining)

3Shape

If the preform is stretched to form the container, then the container takes the desired shape, but the handle structure must be properly positioned and secured during stretching

Engineering Contradiction:

ImproveshapeVSAvoidmanufacturing precision

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A wedge block is introduced as an intermediary tool during the blow-molding process. The wedge block is inserted into the mold cavity and interacts with the handle structure during the stretching and forming operations. This intermediary element helps to properly position, support, and secure the handle as the preform is deformed, ensuring the handle achieves its final correct geometry and position without compromising the overall manufacturing precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables the efficient and integrated formation of containers with handles, reducing process steps and enhancing manufacturing efficiency by forming the handle and container body in a single molding process.

Implementation Method 1

heating a preform having an integral handle in a first oven

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

blowing air into the preform

Methodology Applied

Scientific EffectGas pressure expansion: Pressure Increase

Implementation Method 3

heating the preform in a second oven

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS10335993B2Manufacturing method for forming a container from a preform with a handle notch

Publication Date: 2019.07.02 DT INVENTIONS LLC

AI summary

A method for forming a container with an integral handle includes heating a preform having an integral handle in a first oven, stretching the preform, closing a first mold having a first mold recess and a second mold having a second mold recess around the preform, and blowing air into the preform. A handle pocket wedge block is inserted into a handle pocket of the integral handle of the preform within the first mold and the second mold.