Thermoplastic Socket Layer Thickness Control
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Solution Overview
Problem
Existing methods for manufacturing sockets for connecting fluid conduits to containers made from thermoplastic synthetic materials face challenges in achieving desired layer thickness and relative positioning, particularly when trying to produce thicker layers using co-injection or monosandwich processes, as materials with different melting temperatures and flow behaviors cannot be easily combined in a single injection process.
Innovation Solution
The method involves forming a first material arrangement through extrusion or injection molding into a plane film or hose, then deep drawing or blow molding it into a socket preform, and applying a second material arrangement using injection molding, allowing for the selection of layer thickness and position to achieve the desired wall thickness and strength, with options for fusion and diffusion barrier layers to ensure a strong joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If co-injection or monosandwich process is used to produce multi-layer sockets, then the socket can be manufactured with integrated layers, but the layer thickness and relative positioning cannot be freely selected and thicker external layers cannot be produced
Solution Approach 1:
The manufacturing process is divided into two independent stages: first producing the preform with the first material arrangement (containing diffusion barrier layers), then separately injecting the second material arrangement (structural layers) around it. This segmentation allows each stage to be optimized independently, enabling free selection of layer thicknesses and positions without the constraints of simultaneous multi-layer injection.
Solution Approach 2:
The first material arrangement is formed into a preform before the second material arrangement is injected. This preliminary action establishes the inner structure and diffusion barrier layers first, allowing the outer structural layers to be added subsequently with controlled thickness and positioning, achieving both functional and structural requirements.
2Adaptability or versatility
If materials with different melting temperatures and flow behaviors are combined in a single injection process, then multi-material sockets can be produced, but the process becomes extremely difficult or impossible
Solution Approach 1:
The injection process is segmented into two separate stages: first injecting materials with different properties (diffusion barrier materials) to form the preform, then injecting structural thermoplastic materials to form the outer layers. This eliminates the need to simultaneously process incompatible materials in one injection, making multi-material combination feasible.
Solution Approach 2:
The first material arrangement acts as an intermediary structure that is formed first and then serves as the core around which the second material arrangement is injected. This intermediary approach allows materials with vastly different properties (such as metalized layers vs. thermoplastics) to be combined without direct interaction during the same injection process.
3Strength
If the first material arrangement is made thinner than the second arrangement, then the socket can achieve desired wall thickness and strength, but the skin layer becomes very thin (maximally approximately 2 mm) compared to the core layer
Solution Approach 1:
The socket structure is segmented into functional layers (diffusion barrier in the first material arrangement) and structural layers (in the second material arrangement). This allows the skin layer thickness to be determined by functional requirements rather than being constrained by manufacturing process limitations, enabling optimized thickness ratios for strength and performance.
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 allows for flexible selection of layer thickness and position, enabling the production of sockets with enhanced mechanical strength and diffusion barrier capabilities, overcoming the limitations of traditional methods by allowing materials with different properties to be combined effectively, resulting in a secure and durable connection.
Implementation Method 1
both comprise a thermoplastic material at least as the predominant component and fuse with one another to form a fused joint
Data Source
AI summary
In a method for manufacturing a socket for connecting a fluid conduit to a container made from thermoplastic synthetic material, wherein the socket has a first socket-shaped material arrangement of at least one layer and a second socket-shaped material arrangement of at least one layer, wherein the first material arrangement is thinner than the second material arrangement and the first and second material arrangements are both made of thermoplastic material at least predominantly and fuse with one another to form a fused joint, the first material arrangement is molded by extrusion or injection molding to a plane film or plate or to a hose. The film or plate is deepdrawn or the hose is blowmolded to a first preform with a socket contour. The second material arrangement is applied onto one side of the first preform in a socket contour by injection molding, coinjection or a monosandwich process.