Variable Thickness Preform Design for Lightweight Bottle Production

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Solution Overview

Problem

Current plastic bottle preforms require more material than necessary, leading to increased petroleum usage and weight, while also being susceptible to damage during the blow-molding process due to uneven heating and structural weaknesses.

Innovation Solution

A redesigned preform with a thinner upper segment and thicker lower segment, featuring a support ring, internal and external columns, and a tapered neck portion to reduce material usage and enhance structural integrity, allowing for efficient blow-molding and lighter weight bottles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional preform design with uniform wall thickness is used, then structural integrity is maintained, but material usage increases and weight increases

Engineering Contradiction:

Improvebottle weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The preform features variable wall thickness with a thinner upper segment (0.6-0.8mm) and thicker lower segment (1.0-1.2mm), optimizing material distribution to reduce overall weight while maintaining structural integrity in critical areas through localized thickness variation

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The preform is divided into distinct segments (upper segment, lower segment, transition zone) with different wall thickness characteristics, allowing each segment to be optimized independently for weight reduction while maintaining overall structural performance

Inventive Principle:

Principle #1Segmentation

2Loss of substance

If preform wall thickness is reduced to decrease material usage, then petroleum consumption decreases, but susceptibility to damage during blow-molding increases

Engineering Contradiction:

Improvepetroleum consumptionVSAvoidresistance to damage during processing

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The transition zone incorporates gradual wall thickness variation and structural reinforcements (columns, ribs) that locally enhance strength without increasing overall material usage, protecting the thinner upper segment during blow-molding while minimizing petroleum consumption

Inventive Principle:

Principle #3Local quality

3Use of energy by moving object

If preform design is optimized for lightweighting, then production energy decreases, but dimensional stability during processing may be compromised

Engineering Contradiction:

Improveproduction energyVSAvoiddimensional stability

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The preform includes pre-formed structural elements (columns, ribs, transition zones) that are created during injection molding to pre-establish dimensional stability, reducing the energy required during subsequent blow-molding while maintaining precise dimensional control

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The preform utilizes strategically placed thicker and thinner zones with different structural characteristics that work together as a composite system, providing dimensional stability in critical areas while reducing overall material usage and production energy

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS10829260B2Preform extended finish for processing light weight ecologically beneficial bottles

Publication Date: 2020.11.10 NIAGARA BOTTLING LLC

AI summary

Disclosed are preforms which incorporate improvements in the region of the neck and upper segment of the body to allow the production of lightweight containers, such as bottles suitable for containing water or other beverages. In accordance with certain embodiments, the improvements include a thinner neck finish area than conventional bottles, where the thinner area is extended into the upper segment of the body portion below the support ring. Reducing the thickness in these areas of the bottle allows for less resin to be used in forming the preform and bottle.