Cap Sealing Element Forming Ring to Prevent Disc Detachment
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Solution Overview
Problem
Existing methods for manufacturing internal sealing elements for caps, such as crown caps, are inefficient and costly, often resulting in detachment issues during the formation process, making large-scale production challenging.
Innovation Solution
A forming device with an axially movable punch and a forming ring, preloaded with springs, is used to shape and constrain plastic material inside the cap's concavity, ensuring a secure and efficient formation of the sealing element without detachment, utilizing a layer of adhesive paint for stability and a lobe-shaped cross-section to create a flared collar for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mould is used to press heated plastic material inside the capsule to form the sealing element, then the sealing element can be formed, but the disc may detach from the bottom of the capsule during the formation process
Solution Approach 1:
A layer of adhesive paint is applied to the bottom of the capsule before inserting the heated plastic material. This preliminary adhesive action ensures the disc remains firmly attached during the subsequent pressing operation, preventing detachment while allowing proper formation of the sealing element.
2Quantity of substance
If existing methods are used to manufacture internal sealing elements, then sealing elements can be produced, but the process is inefficient and costly for large-scale production
Solution Approach 1:
The forming device combines multiple operations into a single integrated process: the mould serves both as a constraint for shaping the plastic material and as a pressing tool for forming the sealing element. This merging of functions enables efficient large-scale production while maintaining quality standards.
3Shape
If the plastic material is pressed to expand and fill empty spaces, then the sealing element shape is formed, but the process becomes complex and difficult to control
Solution Approach 1:
The mould is designed with specific geometric features including a base portion that contacts the plastic material and a wall portion with an opening that defines the collar region. This localized structural design guides the plastic material expansion precisely where needed, achieving complex sealing element geometry through simple, well-defined mould features rather than complex forming processes.
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 solution enables easy and cost-effective large-scale production of internal sealing elements that maintain stability and ensure a fluid-tight seal on bottle necks without detachment, enhancing the efficiency and simplicity of the manufacturing process.
Implementation Method 1
a forming ring (14b) fitted outside on the punch (14a) and slidable axially relative to it, characterized in that the forming ring (14b) is preloaded elastically
Implementation Method 2
utilizing a layer of adhesive paint for stability
Implementation Method 3
pressing the charge with a mould determines the expansion of the charge of heated plastic material adhering to the inner wall of the capsule and thus filling the empty spaces left by the mould
Data Source
Figure 1a~4
Figure 3a~3b
AI summary
Described is a forming device (14) for making a sealing element (4) inside a cap (1), for example a crown, for wine or other drinks, comprising a metal capsule (2) and the sealing element (4), the latter cup-shaped on the capsule (2) for inserting and moulding a plastic material directly inside the concavity (5) of the capsule (2), and having an annular collar (8), which rises from the base (6) for engaging in a sealed fashion with the neck (3) of a bottle. The forming device (14) comprises a punch (14a) which is movable axially, at which is placed the capsule (2) provided with a charge (13) of plastic material, with a forming ring (14b) fitted externally on the punch (14a) and slidable axially relative to said punch (14a) and preloaded elastically so as to remain offset towards the outside with its free head (14c) with respect to the free end (14d) of the punch (14a), when the latter is far from the bottom (7) of the capsule (2). A series of spacer sectors (15) applied on the free head (14e) of the forming ring (14b) keep at a distance the free head from the bottom (7) of the concavity (5) when the punch (14a) is in the compression position of the charge (13) of plastic material, in such a way as to form, between the free head (14c) of the forming ring (14b) moved to surround the free end (14d) of the punch, a forming chamber (16).