Aerosol Container Spin Welding for Universal Valve Assembly

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Solution Overview

Problem

The production of aerosol dispensers is complex and costly due to the need for multiple components and formats, which increases the chances of errors and raises production costs, especially when different products require different outer containers, valves, and product delivery devices.

Innovation Solution

The method involves welding a valve to the outer container and a product delivery device to the valve in a fluid-tight relationship, using spin welding to create a single outer container that can accommodate various valves and product delivery devices, simplifying production and reducing component variability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple components and formats are used for different products, then product versatility is improved, but device complexity and production costs increase

Engineering Contradiction:

Improveproduct versatilityVSAvoidproduction complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The aerosol container is designed with a universal neck configuration that can accommodate multiple valve types and product delivery device formats. The neck includes a valve cup with standardized dimensions and sealing surfaces that work with different valve assemblies, allowing a single container design to serve multiple product lines and dispensing requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The aerosol dispenser is divided into modular components: a standardized outer container with universal neck, interchangeable valve assemblies, and separable product delivery devices. This segmentation allows different combinations of components to be assembled into the same container base, reducing the need for entirely different container designs for each product variant.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple components and formats are used for different products, then product versatility is improved, but production costs increase

Engineering Contradiction:

Improveproduct versatilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The container neck and valve cup are designed as universal components that can be manufactured in high volumes for multiple product variants. By standardizing the neck geometry, sealing surfaces, and attachment mechanisms, the same molded parts can be used across different product lines, achieving economies of scale in manufacturing while still supporting product diversity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple components are used, then product versatility is improved, but the chance of errors increases

Engineering Contradiction:

Improveproduct versatilityVSAvoidassembly error rate

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Instead of designing different containers for each product type, the invention inverts the approach by designing a single standardized container that accepts multiple valve and delivery device configurations. This reduces the number of unique container- valve combinations that need to be assembled and tested, thereby reducing assembly errors.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The valve cup and neck are designed with standardized sealing surfaces and attachment geometries that create equivalent connection interfaces for different valve types. This equipotential design ensures that all valve assemblies attach in the same manner with consistent sealing requirements, reducing variability and potential errors in the assembly process.

Inventive Principle:

Principle #12Equipotentiality

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 minimizes production complexity and costs by allowing a single outer container to be used with multiple formats, reducing the need for multiple containers and valves, and minimizing the risk of errors during assembly.

Implementation Method 1

The method involves welding a valve to the outer container and a product delivery device to the valve in a fluid-tight relationship, using spin welding to create a single outer container

Methodology Applied

Scientific EffectSpin welding: Friction Welding

Data Source

PatentUS10596765B2Method of making an aerosol dispenser having annular seals and method of making an aerosol container therefor

Publication Date: 2020.03.24 PROCTER & GAMBLE CO

AI summary

A method of making an aerosol container suitable for use as an aerosol dispenser. The aerosol container includes at least a valve and product delivery device joined to an outer container. The method has the steps of sealing the valve to the product delivery device and outer container at respective annular welds or other bonds joining the valve to the product delivery and to the outer container. The welds, or other bonds may be concentric, with one circumscribing the other, in the same plane or different planes. Suitable product delivery devices include bags and dip tubes. Suitable welds include spin welds.