Spiral Vacuum Panels for Hot-Fill Container Deformation
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Solution Overview
Problem
Existing blow molded plastic containers for liquid and flowable products face challenges in maintaining structural integrity and aesthetic appeal during hot-fill processes, where volumetric and barometric changes cause deformation and instability, while also requiring minimal plastic usage to reduce manufacturing costs.
Innovation Solution
The design incorporates spirally twisted and curved vacuum panels with a transitional wall, arranged in an odd number configuration about the container's periphery, to distribute volumetric and barometric forces uniformly, preventing deformation and ovalization, and featuring a monolayer or multilayer plastic construction suitable for conventional high-speed manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the container wall thickness is reduced to reduce manufacturing cost, then manufacturing cost decreases, but structural integrity and resistance to deformation during hot-fill process deteriorates
Solution Approach 1:
The container wall is segmented into multiple vacuum panels (typically three to five panels) that can independently deflect and absorb volumetric changes during hot-fill processing. This segmentation allows each panel to act as a shock absorber, protecting the overall container structure from deformation while using less material.
Solution Approach 2:
The vacuum panels are designed to be dynamically responsive to internal pressure changes. During hot-fill, the panels can deflect inward to accommodate volume reduction, then spring back to maintain structural integrity. This dynamic behavior allows thin-walled containers to withstand processing forces without permanent deformation.
2Strength
If vacuum panels are added to resist deformation during hot-fill process, then structural integrity improves, but device complexity increases
Solution Approach 1:
The vacuum panels are merged with the container body as a single integrated blow-molded structure. The panels are formed directly during the blowing process, eliminating the need for separate assembly steps or additional structural components. This integration maintains structural simplicity while providing the necessary deformation resistance.
Solution Approach 2:
The container utilizes flexible thin-walled panels that can deflect under vacuum pressure during hot-fill processing. These thin films are designed with specific geometric configurations (curved surfaces, strategic thickness variations) that allow them to absorb volumetric changes without causing overall container deformation, thereby reducing the need for complex reinforcement structures.
3Stability of the object's composition
If the number of vacuum panels is increased to distribute forces uniformly, then resistance to ovalization improves, but manufacturing complexity increases
Solution Approach 1:
The container employs an asymmetric arrangement of vacuum panels (typically three to five panels) positioned at specific angular intervals around the container circumference. This asymmetric configuration optimizes the distribution of volumetric forces during hot-fill processing, preventing ovalization while maintaining manufacturing simplicity. The asymmetric pattern creates a more uniform force distribution compared to symmetric arrangements.
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 effectively resists deformation and collapse, maintaining structural integrity and aesthetic appeal, while minimizing plastic usage, thus reducing manufacturing costs and enhancing the container's ability to withstand hot-fill processes and rough handling.
Implementation Method 1
Each vacuum panel may be defined as having a generally curved surface, with an upper and lower portion separated by a generally radially extending line. The vacuum panels are responsive to internal pressure changes in the container, and each may be deflected from an initial position to a second position, and may spring back from the second position to the initial position.
Implementation Method 2
In a hot fill process, a product is first added to the container at an elevated temperature (e.g., about 82° C.), which may be near the glass transition temperature of the plastic material. Then, the container is capped. As the capped container and its contents cool, the contents tend to contract leading to a volumetric change, which creates a partial vacuum within the container.
Data Source
AI summary
A multi-sided spiraled plastic container for liquid, flowable, and squeezable products may be suitable for use with food or beverage products packaged by traditional hot-fill processes. The container includes an open top through which the container is adapted to be filled, and a body portion having a shoulder section, which extends downwardly from the open top towards a closed base portion. The body portion has a plurality of vacuum panel pairs which are disposed in a spiral fashion about the body portion and configured for contributing to a superior top load strength of the container.