Blow Molded Toner Container Resin Reduction
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Solution Overview
Problem
Toner containers manufactured through blow molding often have uneven thickness due to constricted portions, leading to increased resin usage and weight, as the resin thickness adjustment is difficult in divided sections.
Innovation Solution
A powder container design that minimizes resin usage by optimizing the shape of the container body through direct blow molding, incorporating a scooping portion and spiral rib to evenly distribute toner and reduce thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the parison thickness is increased to meet the minimum thickness requirement at the constricted portion, then the flame retardancy is maintained, but the amount of resin used increases and the container becomes heavier
Solution Approach 1:
The patent applies local quality by making the parison thickness non-uniform, specifically providing a thicker portion at the constricted region and a thinner portion at other regions. This localized thickness variation ensures flame retardancy is maintained where needed (at the constricted portion) while reducing overall resin usage and container weight in non-critical areas.
2Manufacturing precision
If the parison thickness is uniformly increased to compensate for the thin portion, then the minimum thickness requirement is met, but the resin usage and container weight increase
Solution Approach 1:
Instead of uniform thickness increase, the patent implements local quality variation in parison thickness. The parison is designed with a thicker portion corresponding to the constricted portion of the container and a thinner portion for other areas, achieving both thickness precision where needed and material efficiency overall.
3Shape
If the constricted portion is made narrower to achieve the desired container shape, then the container design requirements are met, but the thickness becomes uneven during blow molding
Solution Approach 1:
The patent applies preliminary action by pre-compensating for the thickness variation that will occur during blow molding. The parison is designed with a thicker portion at the constricted region before molding, anticipating that this area will contact the mold later and be drawn more during the process. This preliminary thickness adjustment ensures uniform final thickness despite the constricted shape.
Solution Approach 2:
The patent addresses the shape-thickness contradiction by implementing local quality variation in the parison design. Different sections of the parison have different initial thicknesses, with the thicker portion positioned to compensate for the constricted area, allowing the final container to achieve both the desired narrow shape and uniform thickness.
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 design reduces the amount of resin needed, resulting in a lighter toner container while maintaining the required minimum thickness for flame retardancy.
Implementation Method 1
a hollow parison made of resin is softened by heating
Implementation Method 2
The inside of the parison is blown with air to draw the parison
Data Source
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AI summary
An object of this disclosure is to reduce differences in the drawn amount of the parison around the mouth of the toner container, thereby reducing the amount of resin for the toner container and the weight thereof. A powder container includes a cylindrical container body to rotate in a horizontal posture, a cylindrical mouth at a first end of the container body, smaller in diameter than the container body, a conveyor to convey the powder inside the container body toward the mouth, a scooping portion deeper in the container body than the mouth, to lift the powder above a powder inlet of a conveying tube inserted from the mouth and drop the powder to the powder inlet, and a radially inner face continuous with an inner end of the scooping portion, extending in a direction crossing the scooping portion and disposed inward in the radial direction than an outermost face of the container body. The radially inner face extends from the mouth toward a second end of the container body and is not inner in the radial direction than an inner rim of the mouth.