Blister Pack Polygonal Surface Segmentation
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Solution Overview
Problem
Conventional blister packs are prone to cracking and breakage due to discontinuities in the material, leading to air and humidity infiltration, increased production costs, and health risks, with limitations on size and production speed.
Innovation Solution
The blister surface is fractioned into small geometric figures like polygons, with deformation occurring at angled lines to distribute tension laterally, reducing stress on the material and allowing for a more consistent thickness and aesthetically appealing design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous and progressive toroid deformation elements are used to form blisters, then the deformation process is smooth and continuous, but the blisters are prone to cracking and breakage due to material discontinuities
Solution Approach 1:
The patent divides the deformation process into multiple discrete stages using sequential punches with progressively larger diameters. Instead of continuous deformation, the blister is formed through segmented drawing operations where each punch creates a controlled deformation stage, reducing stress concentration and preventing cracks while maintaining production efficiency
Solution Approach 2:
The patent employs preliminary positioning and clamping of the aluminum strip before deformation begins. The strip is securely held in place and pre-positioned on the punching surface before each drawing operation, ensuring proper alignment and preventing material failure during the deformation process
2Reliability
If blister sizes are increased to graduate deformation and reduce cracking, then deformation stress is distributed better, but the blisters become larger than necessary and less efficient
Solution Approach 1:
The deformation process is segmented into multiple controlled stages using sequential punches of increasing size. This allows the blister to be formed progressively with controlled stress distribution at each stage, achieving complete deformation without requiring excessive final blister size while preventing cracking through staged stress application
Solution Approach 2:
The patent changes the deformation parameters by using punches with progressively larger diameters in sequence. Each punch applies deformation at a different scale and intensity level, allowing controlled graduation of stress that prevents cracking while maintaining optimal final blister dimensions
3Reliability
If deformation speed is limited to prevent breakage, then blister integrity is maintained, but production speed decreases and costs increase
Solution Approach 1:
The deformation process is divided into multiple rapid sequential stages using automated punching operations. Each stage deforms the blister to a specific degree before the next punch acts, allowing high-speed production while controlling stress accumulation through discrete timing intervals rather than slow continuous deformation
Solution Approach 2:
The patent employs dynamic control of the deformation process where each punch operates at optimized speed and timing. The sequential punches are timed and positioned dynamically to match material response characteristics, enabling high-speed operation without exceeding material stress limits that would cause cracking
4Reliability
If multiple sequential punches are used to fraction deformation, then blister integrity improves and cracking reduces, but the device complexity increases
Solution Approach 1:
Multiple punching operations and deformation stages are merged into a single integrated automated machine. The sequential punches, clamping mechanisms, and positioning systems are combined into one coordinated device that performs all deformation steps in a single production cycle, reducing overall system complexity despite the multi-stage process
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 results in blisters that are less likely to crack, maintain a consistent thickness, and can be produced faster, while providing better insulation and a more appealing design, reducing the frequency of breakages and improving product protection.
Implementation Method 1
obtained by punching a strip 12, for example in aluminum, and by deforming the strip 12 with a punch 20
Data Source
Figure 1~4
Figure 5~7
Figure 8a~11
AI summary
A perfected blister pack (10) comprises at least one blister (11). The blister (11) has part of its surface defined by polygonal surfaces (14).