Variable Displacement Container Base Diaphragm Design
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Solution Overview
Problem
Plastic containers used for hot-filled liquids face deformation issues due to thermal and pressure changes, making them non-functional or visually unappealing, and existing vacuum panel technologies are not aesthetically pleasing and limited in their ability to accommodate varying pressures and cooling rates.
Innovation Solution
A container base design featuring a diaphragm structure with radiused portions and ribs that allows for controlled deformation under pressure differentials, accommodating both positive and negative pressures, and maintaining shape integrity during cooling, while being lightweight and aesthetically appealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum panels are added to control deformation, then container functionality is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The patent removes the vacuum panel from the container body and relocates it to the base portion. This extraction allows the vacuum panel to perform its deformation control function while being positioned where it is less visually prominent, thus maintaining aesthetic appearance while preserving functionality.
Solution Approach 2:
The patent transitions the vacuum panel from a two-dimensional surface feature to a three-dimensional base structure with varying thickness. By embedding the vacuum panel within the base's volumetric geometry, the design achieves both functional performance and aesthetic integration, as the panel becomes part of the base's structural form rather than a separate surface element.
2Adaptability or versatility
If base area is reduced to expand container shape, then container versatility is improved, but vacuum panel performance deteriorates
Solution Approach 1:
The patent applies local quality by varying the base thickness at different radial positions. The base is thicker at the periphery where vacuum panel performance is needed and thinner at the center, allowing the container to achieve an expanded shape while maintaining sufficient base area and material volume for effective vacuum panel operation.
Solution Approach 2:
The patent compensates for reduced base area by utilizing the vertical dimension through variable thickness. The base extends further radially while maintaining appropriate thickness in critical zones, effectively increasing the functional base area without increasing the overall container footprint, thus preserving vacuum panel performance while enabling shape flexibility.
3Weight of moving object
If material thickness is reduced to lighten container, then container weight is improved, but structural strength deteriorates
Solution Approach 1:
The patent redistributes material thickness across different radial zones of the base. By concentrating material where structurally necessary (thicker periphery) and reducing it where less critical (thinner center), the design achieves overall weight reduction while maintaining sufficient structural strength through optimized three-dimensional material distribution.
Solution Approach 2:
The patent employs curved, radiused transitions between different base thickness zones rather than abrupt changes. These smooth curved transitions create gradual stress distribution throughout the base structure, preventing stress concentration points and maintaining structural integrity even with varying thickness profiles that reduce overall material usage.
4Manufacturing precision
If base thickness is varied to control deformation, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the base into distinct radial zones with different thickness characteristics (thinner central portion, thicker peripheral portion). This segmentation allows each zone to be optimized independently for its specific function, achieving precise deformation control through simplified, modular thickness variations rather than complex continuous gradients.
Solution Approach 2:
The patent uses smooth radiused transitions between different base thickness zones to avoid abrupt geometric changes. These curved transitions simplify the manufacturing process by creating gradual, continuous geometry that is easier to mold and fabricate, while still achieving the precise deformation control needed through the varying thickness profile.
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 base design provides uniform and controlled deformation, maintaining container integrity and appearance under various pressure and temperature conditions, enhancing the container's functionality and visual appeal.
Implementation Method 1
a base for a container... including an outer support wall, a support surface extending radially inward from the outer support wall and defining a reference plane, an inner support wall extending upwardly from the support surface, a first radiused portion extending radially inward from the inner support wall and concave relative to the reference plane, a second radiused portion extending radially inward from the first radiused portion and convex relative to the reference plane
Implementation Method 2
Plastic containers, used for filling with juices, sauces etc., often are hot filled and then cooled to room temperature or below for distribution to sell. During the process of hot filling and quenching, the container is subjected to different thermal and pressure scenarios that can cause deformation
Data Source
AI summary
Base includes an outer support wall, a support surface extending inwardly from the outer support wall and defining a reference plane, an inner support wall extending upwardly from the support surface, a first radiused portion extending radially inward from the inner support wall and concave relative to the reference plane, a second radiused portion extending radially inward from the first radiused portion and convex relative to the reference plane, an intermediate surface extending radially inward from the second radiused portion, the intermediate surface including a linear portion and an intermediate radiused portion, a third radiused portion extending radially inward from the intermediate surface and convex relative to the reference plane, and a central portion disposed proximate the third radiused portion.