Cap Manufacturing Sliding Layer Extraction
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Solution Overview
Problem
The existing methods for manufacturing caps that seal can containers face challenges such as restricted molding of sealing members due to locking protrusions and potential contamination during vent slit processing, which decrease production efficiency.
Innovation Solution
A manufacturing method involving the use of a sliding layer and a sealing layer made from different resin materials, where the sliding layer is not bonded to the cap body and is used to facilitate the insertion of a sealing member into the cap, allowing for separate molding and processing without contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sealing member is molded inside the cap body and then processing such as forming a vent slit in the skirt portion of the cap main body is performed, then the sealing member and vent slit molding die come into contact with each other, but this causes contamination or the like in the sealing member
Solution Approach 1:
The sealing member is extracted (removed) from the cap body before the vent slit formation process. This allows the vent slit to be formed in the skirt portion without the molding die coming into contact with the sealing member, thereby preventing contamination while maintaining manufacturing efficiency
Solution Approach 2:
The sealing member is removed from the cap body in advance (before) the vent slit formation process. This preliminary action prevents the potential contamination issue that would occur if the sealing member remained in place during subsequent processing steps
2Reliability
If the locking protrusion is formed on the skirt portion of the cap body, then the sealing member is locked, but the outer diameter of the molding die of the sealing member is required to be smaller than the inner diameter of the locking protrusion, which restricts molding or shape of the sealing member
Solution Approach 1:
The sealing member is extracted from the cap body before vent slit formation processing. This sequential arrangement eliminates the need for the molding die to pass through or contact the sealing member, removing the dimensional constraint that limited sealing member design freedom
Solution Approach 2:
The sealing member is removed in advance before the vent slit is formed. This preliminary removal allows the molding die to access the skirt portion freely without being constrained by the presence of the sealing member, thereby enabling greater design flexibility
3Object-affected harmful factors
If the sealing member is removed from the cap body before vent slit molding, then contamination is prevented, but the number of steps of inserting and removing the sealing member increases, which may lower production efficiency
Solution Approach 1:
The removal of the sealing member and the vent slit formation process are merged into a single integrated operation. The molding die that forms the vent slit simultaneously removes the sealing member, eliminating separate insertion/removal steps and maintaining high production efficiency while preventing contamination
Data Source
AI summary
A manufacturing method of a cap (100) includes: supplying a first resin material to a molded product (111A) having a top plate portion (121) and a skirt portion (122) integrally formed on the top plate portion (121) through a corner portion (123); molding the first resin material of the molded product (111A) disposed in a first lower mold (21) into a sliding layer (141) with a first upper mold (22); supplying a second resin material to the sliding layer (141); molding the second resin material of the molded product (111A) disposed in a second lower mold (31) into a sealing layer (142) with a second upper mold (32); taking out a sealing member (112) in the molded product (111A); and inserting the sealing member (112) into another molded product (111A).