Two-Step Injection Molding Container with Collapsible Core
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Solution Overview
Problem
Existing methods for producing pharmaceutical and medical containers, such as injection blow molding, face challenges with long cycle times, high energy and material consumption, and heterogenic wall thickness, which affect sustainability and production costs.
Innovation Solution
The use of a two-step injection molding method with a collapsible core allows for the production of containers with reduced average wall thickness, lower standard deviation of wall thickness, and more uniform wall thickness distribution, thereby reducing material and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If three-step injection blow molding is used, then containers can be produced with adequate wall thickness, but cycle time increases and productivity decreases
Solution Approach 1:
The patent combines the pre-forming and final-forming steps into a single injection molding operation. The injection mold includes a movable core member that defines the container interior, allowing the container to be formed in one step rather than through separate pre-forming and blowing steps. This merging of operations reduces cycle time while maintaining wall thickness uniformity through precise control of the injection process and core member movement.
2Adaptability or versatility
If three-step injection blow molding is used, then containers can be produced with complex shapes, but energy consumption increases
Solution Approach 1:
The patent extracts the hot gas blowing step from the traditional three-step process, replacing it with a cold or warm injection molding approach. The movable core member is moved during injection to create complex container shapes directly, eliminating the need for subsequent heating and blowing operations. This extraction of the thermal process significantly reduces energy consumption while maintaining the ability to produce complex shapes through controlled core member movement and injection parameters.
3Strength
If three-step injection blow molding is used, then containers can be produced with adequate structural integrity, but material consumption increases
Solution Approach 1:
The patent changes the processing parameters from high-temperature blowing to controlled injection molding with a movable core. By adjusting injection pressure, temperature, and core member movement timing, the process achieves adequate structural integrity with thinner, more uniform walls. The direct injection molding approach allows precise control of material distribution, reducing excess material usage while maintaining container strength through optimized molding parameters rather than relying on thick walls from the blowing process.
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 significantly reduces material consumption by 50% and energy consumption by 86% compared to traditional three-step injection blow molding, enhancing the sustainability of container production.
Implementation Method 1
injecting material into the molding chamber formed between a cavity member defining an exterior surface of the container and a core member defining an interior surface of the container
Implementation Method 2
wherein the core member collapses for passing the undercut section
Data Source
AI summary
The disclosure relates to a container, such as a primary packaging container for pharmaceutical, medical, cosmetic, dietetic and/or food products. The container may include an interior surface with at least one undercut section. At least a portion of the container may have an average wall thickness of maximally 0.8 mm, between 0.2 mm and 0.8 mm, between 0.3 mm and 0.7 mm, or between 0.4 mm and 0.6 mm.