Self-Collapsing Blow-Molded Thin-Walled Container
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Solution Overview
Problem
Existing large-capacity plastic jugs for water dispensing units are cumbersome, prone to mechanical damage, and suffer from air contamination during use, posing handling and sanitary issues, while previous thin-walled container solutions lack sufficient volume capacity and durability.
Innovation Solution
Development of blow-molded plastic thin-walled containers with a self-collapsing design, featuring a collapsible structure that maintains airtightness and mechanical strength, allowing for efficient handling and storage, and utilizing a manufacturing method involving stretch blow molding with specific stretching ratios and structural features like transversal grooves and retractable parts for enhanced compactability and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the wall thickness of plastic jugs is increased to 400-1500 μm to improve mechanical strength and resistance to abrasion, then the jugs become difficult to lift and manoeuvre due to increased weight and bulk
Solution Approach 1:
The invention divides the container into two distinct parts: a thin-walled collapsible body (50-200 μm) for liquid storage and a separate thick-walled rigid base (400-1500 μm) for mechanical support. This segmentation allows each part to optimize its thickness for its specific function, resolving the contradiction between overall strength and weight.
Solution Approach 2:
The invention applies different wall thicknesses to different parts of the container based on local functional requirements. The base and neck areas receive thick walls (400-1500 μm) for structural integrity and abrasion resistance, while the body uses thin walls (50-200 μm) to minimize weight and enable collapsibility.
2Weight of moving object
If thin-walled bottles are used to reduce weight and improve handling, then they become prone to mechanical damage and lack sufficient durability for returnable and refillable use
Solution Approach 1:
The invention applies different wall thicknesses to different parts of the container based on local functional requirements. The base and neck areas receive thick walls (400-1500 μm) for structural integrity and abrasion resistance, while the body uses thin walls (50-200 μm) to minimize weight and enable collapsibility.
Solution Approach 2:
The container functions as a composite structure combining thin-walled flexible plastic for the body with thick-walled rigid plastic for the base and neck, creating a hybrid system that exhibits both collapsibility and mechanical durability.
3Strength
If rigid jugs are used to maintain structural integrity, then air enters the liquid during sampling to compensate for sampled volume, causing contamination
Solution Approach 1:
The invention transforms the static rigid structure into a dynamic collapsible structure. The thin-walled body can deform and collapse as liquid is dispensed, maintaining a seal that prevents air from entering the liquid, thereby eliminating contamination while preserving structural integrity through the rigid base.
4Productivity
If empty jugs are made rigid and returnable for refilling, then they require washing and treatment involving sanitary issues and organization of delivery circuits
Solution Approach 1:
The invention employs a disposable thin-walled container design that eliminates the need for complex washing and refilling circuits. The thin-walled body can be easily separated and discarded after use, significantly simplifying sanitary management and logistics while maintaining productivity through continuous availability of new containers.
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 solution provides a cost-effective, airtight, and durable thin-walled container that can handle large volumes, prevents air contamination during use, and facilitates easy handling and storage by self-collapsing when empty, addressing the issues of bulkiness and sanitary concerns of previous designs.
Implementation Method 1
heating and stretching, in the axial and radial directions, by blow molding
Implementation Method 2
blow molding of a preform, with heating and stretching, in the axial and radial directions
Implementation Method 3
which, when empty, is capable of collapsing, under the effect of its own weight, in the axial direction
Data Source
Figure 1A
Figure 1B
Figure 1A'~1D
AI summary
A blow molded bottle (1): a) which is self-collapsable during its emptying; b) which comprises at least two transversal grooves and/or ribs (6.1), preferably located in the tubular body portion (6), equipped with collapse starters (6.2); c) wherein the mean wall thickness (Tmean) of the tubular body portion (6) is - in an increasing order of preference - less than or equal to 200 μm preferably comprised between 90 and 130 μm. The invention also concerns a method, a preform (100) and a mold for the manufacture of said aforementioned container by blow moulding. The invention also concerns a method for bottling liquid into said bottles (1), a method for dispensing said liquid, a dispenser for implementing said method and a method for packing the thin-walled bottles, in view of storage and transportation.