Closure Gasket Integration via Rotating Core Injection Molding
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Solution Overview
Problem
Existing methods for creating closures with gaskets for liquid containers are costly and often have limited performance, as gaskets are typically formed separately and installed manually or mechanically, rather than being integrated directly into the closure during molding.
Innovation Solution
A method using a dual injection molding machine with a center rotating cube, where cores with a thread unscrewing mechanism form a closure with a through hole, creating a gap for injecting a compressible material to form a sealing gasket, which can be made of thermoplastic elastomer or other sealing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If gaskets are formed separately and installed manually or mechanically, then the closure can be produced, but the production cost increases and performance is limited
Solution Approach 1:
The patent combines the closure and gasket into a single integrated component formed by one molding cycle. The gasket is formed directly within the closure body during the same injection molding process, eliminating separate manufacturing and assembly steps. This merging of components reduces production cost while ensuring reliable sealing performance through precise integration.
Solution Approach 2:
The gasket is pre-formed within the closure during the initial molding process before any assembly operations. The injection molding process creates the gasket in its final positioned state within the closure body, preparing the complete sealed unit in advance and eliminating subsequent assembly steps that would increase cost and complexity.
2Ease of operation
If gaskets are formed separately and installed manually, then the closure can be assembled, but production time increases and productivity decreases
Solution Approach 1:
The closure and gasket are formed as a single integrated component in one molding cycle, eliminating the need for separate assembly operations. This combining of manufacturing steps transforms a multi-step process into a single-step process, dramatically improving productivity while simplifying the operational process.
Solution Approach 2:
The molding process automatically forms the gasket within the closure body without requiring manual or mechanical assembly operations. The injection molding machine performs all necessary actions to create both the closure and integrate the gasket in one automated cycle, eliminating labor-intensive assembly steps and improving production efficiency.
3Ease of manufacture
If a single injection molding machine is used to form both closure and gasket, then production cost decreases, but the molding process complexity increases
Solution Approach 1:
The patent uses a single injection molding machine to perform both closure and gasket formation in one cycle, consolidating what would traditionally require multiple machines and steps. This merging of functions into a single device reduces overall manufacturing complexity despite the advanced capabilities required, while significantly lowering production cost through elimination of multiple machines and assembly operations.
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 method enables the cost-effective and efficient integration of a sealing gasket directly into the closure during molding, enhancing the sealing performance and reducing production costs by eliminating separate gasket installation steps.
Implementation Method 1
a method of forming a closure with a sealing gasket in an injection molding machine
Implementation Method 2
injecting a compressible material through the through hole and into the gap to form a sealing gasket
Data Source
AI summary
What is presented is a method of forming a closure with a sealing gasket in an injection molding machine that has a center rotating cube. The center rotating cube comprises a plurality of mold back halves each comprising cores and a thread unscrewing mechanism. Each core is shaped to form a closure that has a thread and an anti-rotation feature. The method comprises the steps of forming a closure with a through hole, rotating the core to create a gap between the formed closure and the core, and injecting a compressible material through the through hole and into the gap to form a sealing gasket.