Bistable Elastomeric Cap Applicator for Semi-Solid Refill
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Solution Overview
Problem
Existing applicators for semi-solid materials, such as lip balm and sunscreen, are not easily refillable, environmentally friendly, or user-friendly, lacking in design simplicity and versatility for effective application.
Innovation Solution
A tubular applicator with a bistable elastomeric base cap and a plunger system that allows for easy access and extension of the semi-solid material, featuring a removable end cap, a tray, and a guide for precise movement, enabling efficient application and easy replacement of the semi-solid material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional applicator design is used, then the structure is simple, but the applicator is not easily refillable and environmentally friendly
Solution Approach 1:
The applicator is divided into separable components: a reusable housing containing a plunger mechanism and a removable cartridge that holds the semi-solid material. This segmentation allows the cartridge to be easily removed and replaced, enabling refilling without discarding the entire applicator, thus improving refillability while maintaining reasonable structural complexity
Solution Approach 2:
The plunger mechanism incorporates a spring-loaded system that dynamically adjusts the position of the semi-solid material. The plunger can move between retracted and extended positions, allowing the material to be stored compactly when not in use and deployed easily when needed, facilitating easy refilling and environmental friendliness
2Adaptability or versatility
If a complex applicator design is used, then the applicator may be refillable and environmentally friendly, but the design becomes less simple and more difficult to manufacture
Solution Approach 1:
The housing is designed as a universal component that can accommodate different cartridges containing various semi-solid materials. The standardized interface between the housing and cartridge allows the same housing to be used with multiple material types, improving adaptability and environmental friendliness while maintaining manufacturing simplicity through standardized production processes
Solution Approach 2:
The design enables selective discarding of only the used cartridge while recovering and reused the housing and plunger mechanism. This approach improves environmental friendliness by reducing waste compared to disposable applicators, while the modular nature of the components keeps manufacturing relatively simple and cost-effective
3Ease of manufacture
If a simple applicator design is used, then the manufacturing cost is low, but the applicator lacks versatility and ease of use for effective application
Solution Approach 1:
The spring-loaded plunger mechanism is designed to automatically extend the semi-solid material when the user presses the applicator, eliminating the need for manual manipulation of the material. The mechanism self-regulates the extension and retraction of the material, improving ease of use while keeping the overall design simple and cost-effective to manufacture
Solution Approach 2:
The semi-solid material is pre-positioned in the cartridge and the plunger is pre-loaded with spring tension during manufacturing. This preliminary preparation ensures that when the user activates the applicator, the material is already positioned and ready for immediate application, improving ease of use without adding significant manufacturing complexity
4Duration of action of stationary object
If a traditional applicator design is used, then the structure is straightforward, but the shelf life is short and environmental impact is high
Solution Approach 1:
The semi-solid material is extracted from the housing and stored in a separate, sealed cartridge. This extraction allows the material to be protected from environmental factors such as moisture and contamination during storage, extending shelf life. The sealed cartridge design prevents degradation while maintaining a relatively simple overall structure
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 design provides a simple, cost-effective, and environmentally friendly solution for applying semi-solid materials, ensuring easy refilling and prolonged shelf life while enhancing user experience through efficient and precise application.
Implementation Method 1
An elastomeric material base cap closing the housing first end... the elastomeric material base cap may be concave in relaxed position so as to bias the semi-solid material to the second position extending at least partially out of the second end of the housing
Implementation Method 2
the elastomeric material base cap is a bistable element which moves from a first stable configuration in which the semi-solid material is primarily within the housing to, after removal of the end cap and manual actuation thereof, a second stable configuration in which the semi-solid mass is substantially completely exterior of the housing
Data Source
AI summary
An applicator for a stick product, such as lip balm, has a generally tubular housing closed at one end by an elastomeric base cap and at the other by an end cap. The base cap is connected to one end of a plunger shaft, and at the other end the shaft is connected to a tray holding a semi-solid mass of the stick product. The end cap is in the form of a mold so that the stick product may be molded onto the tray in situ. The end cap locks to the housing to cover the semi-solid mass, and when removed the base cap (e. g. durometer 70A), which is bistable, having two relaxed configurations, may be depressed to move the mass out of the housing. The plunger and stick product are easily replaced.