plastic bottle design
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GROUP ONE, LTD.Marc BranderMike Holzer
Benny KirchnerTyrel Ruch
PRODUCT GOALS
PRODUCT GOALS• Design a unique container for a new liquid soap product.• Container needs to hold 28-32 fluid oz. of product.• Container must have a method for seeing remaining product.
PRODUCT GOALS• Container should be aesthetically pleasing.• Container sizing should fit within the “Golden Section,” or a ratio of 1:1.618 width to height.
PRODUCT GOALS• The container must be designed ergonomically to make it useful to its purpose. It must fit the hand, and require only a reasonable amount of force to dispense the product.
PRODUCT GOALS• Provision must be made for application of a customer supplied product label.• The customer would prefer a raised surface on which to affix their label.
MATERIAL SELECTION
MATERIAL SELECTION
Per customer request, the original design specification called for ABS plastic as the material for this bottle.
MATERIAL SELECTION
However, research conducted at our expense has indicated PET (Polyethylene Terephthalate) would be better suited for this product.
MATERIAL SELECTION
Reasons for this material change include:
• Material Property Advantages• Raw Material Cost• Recyclability
MATERIAL SELECTION: MATERIAL PROPERTIES
The material properties of PET offer a distinct advantage to ABS for the following reasons:
MATERIAL SELECTION: MATERIAL PROPERTIES
1. PET can be produced with 99% optical clarity, compared to 79% with ABS.
2. ABS is a type of styrene known for its durability and impact resistance.
MATERIAL SELECTION: MATERIAL PROPERTIES
3. Due to its durability and impact resistance, ABS provides a stiffer wall, causing a need for greater force to be exerted in this squeeze bottle application.
MATERIAL SELECTION: MATERIAL PROPERTIES
4. ABS offers a poor surface finish and requires secondary coating processes to produce a smooth or glossy appearance.
MATERIAL SELECTION: MATERIAL PROPERTIES
5. PET will produce clear, glossy bottles needing no secondary processes.
6. PET is better suited to both Extrusion Blow Molding and Stretch Blow Molding.
MATERIAL SELECTION:RAW MATERIAL COSTS
PET and ABS are both traded on an open market. For this reason, material pricing for both fluctuates periodically.
MATERIAL:RAW MATERIAL COSTS
Regardless of the fluctuation, virgin PET pellets (raw material) can be obtained at a lower cost than ABS.
MATERIAL:RAW MATERIAL COSTS
Prices Listed are Per Pound
ABS $2.42 $0.83 $1.43 $1.25 $0.66 $0.96 $1.15 $0.68 $0.91 ABS (30% glass) $1.25 $1.25 $1.25 ABS - Medium Impact $0.89 $0.85 $0.87 ABS - High Impact $0.86 $0.86 $0.86 $1.24 $1.24 $1.24 Polcarbonate + ABS $4.25 $3.93 $4.09 $2.60 $0.90 $1.75 Polycarbonate + PET (Imp. Mod) $2.87 $2.87 $2.87 HDPE $0.82 $0.57 $0.67 $0.89 $0.49 $0.72 $0.79 $0.53 $0.64 HDPE (widespec, virgin) $0.42 $0.42 $0.42 HDPE (co-pp) $0.36 $0.36 $0.36 LDPE $0.94 $0.94 $0.94 $0.80 $0.72 $0.76 LLDPE $3.30 $1.40 $2.35 $0.93 $0.93 $0.93 $0.85 $0.50 $0.70 PET $1.50 $1.28 $1.43 $0.67 $0.67 $0.67 $0.70 $0.45 $0.56
Generic High Low Avg. High Low High Low Avg.
Source: IDES Plastics "The Plastics Web." Retrieved 2008-10-23, from http://www.ides.com/resinprice/resinpricingreport.asp
Less than 10,000 lbs. 10,000 - 100,000 lbs. Greater than 100,000 lbs
Avg.
MATERIAL SELECTION: RECYCLABILITY
Re-use and recycling is becoming a major consideration in corporate responsibility in the current global economy.
MATERIAL SELECTION: RECYCLABILITY
For this reason, PET is a more sensible choice ecologically, as it is more widely accepted in recycling programs nationwide.
MATERIAL SELECTION: RECYCLABILITY
Number 1 PlasticsPET/PETE (Polyethylene Terephthalate)
Found in: Soft drink, water and beer bottles; mouthwash bottles; soap bottles; peanut butter containers; salad dressing and vegetable oil containers.
Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
MATERIAL SELECTION: RECYCLABILITY
Recycling: Picked up through most curbside recycling programs.
Recycled into: Polar fleece, fiber, tote bags, furniture, carpet, paneling, straps, (occasionally) new containers.
Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
MATERIAL SELECTION: RECYCLABILITY
PET plastic is the most common for bottles because it is inexpensive, lightweight and easy to recycle. It poses low risk of leaching breakdown products. Recycling rates remain relatively low (around 20%), though the material is in high demand by remanufacturers.
Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
MATERIAL SELECTION: RECYCLABILITY
Number 7 Plastics Miscellaneous Found in: Three- and five-gallon water bottles, sunglasses, DVDs, iPod and computer cases, signs and displays, certain food containers, nylon
Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
MATERIAL SELECTION: RECYCLABILITY
Recycling: Number 7 plastics have traditionally not been recycled, though some curbside programs now take them.
Recycled into: Plastic lumber, custom-made products
Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
MATERIAL SELECTION: RECYCLABILITY
ABS plastic, which is classified as a Number 7, is one of a wide variety of plastic resins that don't fit into any of the other categories.
Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
MATERIAL SELECTION: RECYCLABILITY
As an incentive, your own scrap PET or other commercially available recycled PET may be added to your virgin material to produce a cost savings.
PRELIMINARY DESIGN IDEAS
INITIAL DESIGN IDEAS
We considered a number of designs and styles to satisfy your needs. The following are a few of our preliminary design thoughts:
INITIAL DESIGN IDEAS
INITIAL DESIGN IDEAS
INITIAL DESIGN IDEAS
INITIAL DESIGN IDEAS
FINAL DESIGN PROPOSAL
GOLDEN SECTIONThis diagram demonstrates the application of the “Golden Section” of 1.618:1 in the bottles dimensions.
GOLDEN SECTIONAll of the dimensions shown are related to one another using this ratio.
RAPID PROTOTYPING
RAPID PROTOTYPING
Using a Stratysys Dimension SST Rapid Prototyping machine, we were able to create a 1:1 scale 3-dimensional prototype model of our design proposal.
The bottle has been ergonomically designed for easy one handed use.
Using symmetry, the bottle also allows for easy left-hand use.
The bottle shape also allows it to be stood on its top.
COLORATION SUGGESTIONS
COLORATION SUGGESTIONS
Using a third interval color scheme, green, blue green, and blue were added to promote a feeling of harmony.
COLORATION SUGGESTIONS
Using a third interval color scheme, green, blue green, and blue were added to promote a feeling of harmony.
COLORATION SUGGESTIONS
Using a third interval color scheme, green, blue green, and blue were added to promote a feeling of harmony.
COLORATION SUGGESTIONS
Using a fifth interval color scheme, green and violet were added to promote a subtle, yet pleasing appearance.
COLORATION SUGGESTIONS
Using a fifth interval color scheme, green and violet were added to promote a subtle, yet pleasing appearance.
COLORATION SUGGESTIONS
Using a fifth interval color scheme, green and violet were added to promote a subtle, yet pleasing appearance.
COLORATION SUGGESTIONS
Using a seventh interval color scheme, red and green were used to promote a feeling of excitement.
COLORATION SUGGESTIONS
Using a seventh interval color scheme, red and green were used to promote a feeling of excitement.
COLORATION SUGGESTIONS
Using a seventh interval color scheme, red and green were used to promote a feeling of excitement.
FORCE ANALYSIS
FORCE ANALYSIS
Using COSMOS Works, a Finite Element Analysis (FEA) software, we were able to simulate the force required to squeeze this bottle to dispense the product within.
FORCE ANALYSIS
Our results were as follows:
FORCE ANALYSIS• Using a squeezing force of only four pounds, the bottle will deform .330 inches per side.
COSMOS – von MISES STRESS
FORCE ANALYSIS• We feel that four pounds of force is a very reasonable amount of force to exert;
COSMOS – DEFORMATION
FORCE ANALYSIS• and that this amount of deformation should provide sufficient internal pressure to dispense the product.
COSMOS – EQUIVALENT STRAIN
VOLUMETRIC REQUIREMENTS
VOLUMETRIC REQUREMENTS
VOLUMETRIC REQUREMENTS
VOLUMETRIC REQUREMENTS
VOLUMETRIC REQUREMENTS
Initial Volume 63.39 Cubic Inches(-) Final Volume 3.99 Cubic Inches
59.40 Cubic InchesConversion Factor 0.5541125541
32.91 Fluid OuncesSource: Online Conversion.com http://www.onlineconversion.com/volume.htm,
based on the formula 1 cubic inch = 0.554 112 554 1 ounce [US, liquid]
BOTTLE CAP
BOTTLE CAP
We designed this bottle to feature an inverted style cap. This style has gained popularity on a wide variety of products, and we feel that it is ideal for this application.
BOTTLE CAP
We have sourced a cap for this bottle from Zeller Plastics, and the cap is available through McKernan Packaging.
BOTTLE CAP
The neck is produced using the PBI L28SP400 finish, and a number of manufacturers offer similar caps in this size.
BOTTLE CAP
This cap, P/N 3812-28400, is available at a cost of $0.57 each in quantities of 1000.
BOTTLE CAP
The cap shown here features a one way silicone valve to prevent drips and to limit flow.
CAP AND THREAD ALIGNMENT DETAIL
ARE THERE ANY QUESTIONS?
THANK YOU.
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