Multi-layered Thermoplastic Container with Overlapping Seam
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Solution Overview
Problem
Current methods for producing multi-layered blown plastic containers are complex, costly, and inefficient, making it challenging to achieve the desired layer thickness and coherency while maintaining production speed and quality control.
Innovation Solution
A process involving a planar web of thermoplastic substrate, formed into a loose conduit and then blow molded into a container with a calibrated neck and overlapping seam, using a conformer and blow mold to create a one-piece container with a plug seal closure, allowing for simpler and more cost-effective production of multi-layered containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If co-extrusion or over-molding processes are used to form multi-layer containers, then the desired layer thickness and coherency can be achieved, but the production cost increases and production speed decreases
Solution Approach 1:
The container is formed in multiple stages: first creating a single-layer container, then separately forming and bonding additional layers. This segmentation allows each layer to be optimized independently while maintaining overall production efficiency, resolving the contradiction between achieving precise layer coherency and maintaining high production speed.
Solution Approach 2:
The base container is formed completely before adding subsequent layers. This preliminary action allows the first layer to be produced at high speed using simple extrusion, while later layers are added in controlled steps that ensure proper thickness and coherency without slowing down the overall production cycle.
2Manufacturing precision
If co-extrusion or over-molding processes are used to form multi-layer containers, then the desired layer thickness and coherency can be achieved, but the production complexity increases
Solution Approach 1:
The multi-layer forming process is divided into separate, independent stages where each layer is formed and bonded separately. This segmentation simplifies each individual step, allowing the use of standard, well-understood extrusion and bonding equipment rather than requiring complex co-extrusion or over-molding machinery.
Solution Approach 2:
A bonding agent or intermediate layer is used to join the separately formed layers. This intermediary simplifies the joining process by providing a standardized interface between layers, eliminating the need for complex integrated forming systems and allowing each layer to be produced using simple, reliable equipment.
3Manufacturing precision
If quality control is strengthened to ensure layer coherency in multi-layer containers, then the desired manufacturing precision is achieved, but the production cost increases
Solution Approach 1:
The bonding process is designed to be self-regulating, where the bonding conditions and parameters automatically ensure proper layer coherency without requiring extensive external quality control interventions. The process inherently produces consistent results, reducing the need for additional quality control equipment and personnel.
Solution Approach 2:
Complex mechanical quality control systems are replaced with simpler process controls. By optimizing the bonding parameters and using self-regulating bonding mechanisms, the system achieves consistent layer coherency through process design rather than through complex measurement and adjustment systems, thereby reducing production costs.
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 enables the production of multi-layered containers with improved layer coherency and reduced production complexity, enhancing cost-effectiveness and quality control while maintaining the desired thickness and structural integrity.
Implementation Method 1
a one-piece thermoplastic substrate
Implementation Method 2
blown into a container
Data Source
AI summary
A package including: a container; and a plug seal closure operatively engaged with an open end of the container; wherein the container has; a closed end opposing the open end; a container wall extending longitudinally between the closed end and the open end about a longitudinal axis; an end seam extending at least partially across the closed end; and a longitudinal overlapping seam extending from the end seam, a portion of the overlapping seam extending longitudinally along the container wall between the closed end and the open end; wherein the open end is narrower than at least a portion of the container away from the open end of the container; and wherein the closed end and the container wall consist of a one-piece thermoplastic substrate.