Cosmetic Compact Hinge Durability via Segmented Injection Molding

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Solution Overview

Problem

Cosmetic compacts with plastic hinges are prone to breaking under stress, and conventional manufacturing processes require separate labeling steps, increasing costs and compromising product durability.

Innovation Solution

A cosmetic compact design that incorporates labeling during assembly, using injection molding to create a durable hinge and outer wrap material that is affixed to the panels, allowing for a sleek design and enhanced durability, with magnets for secure closure and angle control tabs for adjustable opening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional injection molding techniques are used to form the body and cover with plastic hinges, then the manufacturing process is simple and cost-effective, but the hinges are prone to breaking under stress

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidhinge durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The hinge is divided into two separate components: a first hinge portion molded into the cover and a second hinge portion molded into the body. These segmented portions are then assembled together using interference fit and adhesive bonding, distributing the stress and improving overall hinge durability while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hinge assembly combines different plastic materials with complementary properties: a rigid plastic for structural strength and a flexible plastic for stress absorption. This composite approach allows the hinge to withstand repeated opening and closing cycles without breaking.

Inventive Principle:

Principle #40Composite materials

2Productivity

If labeling is performed as an additional step after assembly, then the compact can be manufactured, but the cost of the final product increases considerably

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The labeling operation is merged with the assembly process by pre-attaching labels to components during injection molding. This integration eliminates the need for separate labeling steps, reducing manufacturing complexity and cost while maintaining productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Labels are pre-positioned and pre-attached to components during the molding process before final assembly. This preliminary action ensures proper label placement and eliminates the need for post-assembly labeling operations, reducing overall manufacturing cost.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the outer wrap material edges are visible from the side view, then the assembly process is simpler, but the aesthetic appearance is compromised

Engineering Contradiction:

Improveassembly simplicityVSAvoidaesthetic appearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The outer wrap material is nested within the frame structure, with its edges positioned inside the frame's sidewalls. This nesting arrangement conceals the wrap edges from side views, providing a sleek aesthetic appearance while maintaining simple assembly through the integrated molding process.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 enhances durability and reduces costs by integrating labeling and hinge construction, providing a more robust and aesthetically pleasing product with secure closure and adjustable opening.

Implementation Method 1

a hinge; and an outer wrap material, wherein the top panel, the bottom panel and the hinge are affixed to the outer wrap material in a first step and (1) the frame is fixedly secured the top panel and (2) the platform to be fixedly secured to the bottom panel in a second step

Methodology Applied

Scientific EffectHinge: Hinge

Implementation Method 2

The frame and platform can include magnets

Methodology Applied

Scientific EffectMagnetism: Magnetism

Implementation Method 3

the top panel, the bottom panel and the hinge are affixed to the outer wrap material

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentUS11324301B2Cosmetic compact with paper labeling

Publication Date: 2022.05.10 KORBA GARY

AI summary

A cosmetic compact being incorporated with outer wrap material. The cosmetic compact including a cover, the cover including a frame and a top panel, the frame including four sidewalls; a cosmetic holder, the cosmetic holder including a platform and a bottom panel, the platform including four sidewalls, a hinge; and an outer wrap material, wherein the top panel, the bottom panel and the hinge are affixed to the outer wrap material in a first step and (1) the frame is fixedly secured the top panel and (2) the platform to be fixedly secured to the bottom panel in a second step thereby allowing the outer wrap material to be incorporated into the cosmetic compact.