Preform Neck Crystallization Method for Wide-Neck Containers
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Solution Overview
Problem
Wide-neck containers face challenges in crystallizing the neck without overheating, which can lead to deformation and affect seal-tightness, as existing methods rely heavily on external heating sources and lack control over temperature gradients during the crystallization process.
Innovation Solution
A preform neck crystallization method involving a core inserted into the neck, with a heater group that uses a combination of rapid and slow heating steps, along with cooling, to control the temperature within the crystallization zone, and a wide-neck container design featuring a flange and ring-shaped recess to reduce deformation and enhance seal-tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the neck is heated to crystallize it, then heat resistance is improved, but deformation occurs due to volume decrease
Solution Approach 1:
The patent applies different heating powers to different zones along the neck. The heater group includes multiple heaters with different power ratings positioned at different locations, creating localized heating zones that allow the neck to be crystallized uniformly without excessive volume contraction in any single area, thereby preventing deformation while achieving heat resistance.
Solution Approach 2:
The patent dynamically adjusts the heating process by using a combination of high-power and low-power heaters that can be controlled independently. This dynamic heating approach allows for precise temperature control during crystallization, maintaining the neck shape while achieving the required crystallization for heat resistance.
2Strength
If external heating is used to crystallize the neck, then heat resistance is achieved, but temperature control precision deteriorates
Solution Approach 1:
The patent divides the heating system into multiple independent heater units arranged in a group along the neck. Each heater can be controlled independently with different power levels, allowing precise temperature control at different zones of the neck during crystallization, thereby achieving both heat resistance and temperature control precision.
Solution Approach 2:
The patent changes the heating parameters by using multiple heaters with different power ratings rather than a single heating source. This allows for fine-tuned temperature control during the crystallization process, maintaining precision while achieving the required heat resistance through controlled thermal treatment.
3Productivity
If rapid heating is applied to reduce crystallization time, then productivity improves, but temperature uniformity deteriorates causing overheating
Solution Approach 1:
The patent segments the heating system into multiple heaters with different power levels positioned at different locations along the neck. This segmentation allows rapid heating overall while maintaining temperature uniformity through coordinated control of individual heater zones, preventing overheating and achieving quick crystallization.
Solution Approach 2:
The patent uses multiple heating parameters (different power levels for different heaters) to achieve rapid yet uniform heating. By varying the power parameters across the heater group, the system can rapidly increase temperature while maintaining uniformity, reducing crystallization time without causing overheating.
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 reduces crystallization time while preventing overheating and improves seal-tightness by maintaining the neck temperature within the optimal crystallization range, and the container design minimizes deformation and enhances sealing capabilities.
Implementation Method 1
heating the neck using a heater group disposed along a transfer direction
Implementation Method 2
heat from the second heat source (22) is transmitted to the core to heat the neck from the inner side
Implementation Method 3
cooling the neck of the preform in a state in which the core is inserted into the neck
Data Source
AI summary
A wide-neck synthetic resin container has a neck, a body and a bottom. A top side of the neck is sealed by a cap. The neck includes a neck tubular section, an engagement section protruding outward therefrom and engaging the cap, and a flange protruding outward at the top side. The flange protrudes less than the engagement section. The neck's top side includes a first top side formed by the neck tubular section, and a second top side formed by the flange that is the same height level with the first top side and increases an area of the top side. The neck tubular section has a uniform thickness at an area immediately below the flange and an area where the engagement section is formed. A thickness of the flange is smaller than that of the neck tubular section, and the neck has been crystallized.