Cosmetic Containers Using Welded End Caps for Volume and Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cosmetic containers face challenges with reduced product volume due to crimping processes, limited aesthetics, and inability to stand on their closed end, necessitating improved designs and manufacturing methods for enhanced capacity and functionality.
Innovation Solution
The method involves using a thin-walled tube with a first open end and a second open end, attaching a structure for receiving a cap and an aperture for dispensing, and securing the second end with an end cap using a weld fixture and energy application, allowing for alternative materials and constructions such as extruded, laminated, or heat-shrink tubes with pre-made dispensers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimping process is used to close the tubular shell, then the container can be sealed, but the volume of the tubular shell is reduced and product capacity is limited
Solution Approach 1:
The container is divided into separate components: a tubular shell and a separate end cap structure. The end cap is attached to close the open end of the tube, providing sealing capability without deforming or crimping the tubular shell, thereby preserving the full volume of the container.
2Reliability
If a crimping process is used to close the tubular shell, then the container can be sealed, but the aesthetics and storage options are limited
Solution Approach 1:
By separating the sealing function into a distinct end cap component rather than deforming the tube itself, the design achieves both functional sealing and aesthetic flexibility. The end cap can be designed in various shapes and styles, and the tubular shell maintains its original form for better storage options.
3Reliability
If the open end is crimped shut after filling, then the container is sealed, but the container cannot stand on its closed end
Solution Approach 1:
The end cap is designed as a separate structured component with a flat bottom surface, while the tubular shell remains undeformed. This allows the container to stand upright on the end cap's flat surface, providing storage convenience while maintaining the sealing function.
4Ease of manufacture
If traditional molding or extrusion methods are used, then the container can be manufactured, but the manufacturing process is complex and time-consuming
Solution Approach 1:
The tubular shell, end cap, and dispenser are manufactured as separate pre-formed components using optimized processes. This preliminary preparation allows for parallel manufacturing of multiple components, reducing overall production time and simplifying the final assembly process where components are quickly joined together.
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 enables increased product volume, improved aesthetics, and the ability to stand the container on its closed end, while maintaining product integrity and usability, addressing the limitations of traditional crimping methods.
Implementation Method 1
securing the second open end of the thin-walled tube to the end cap piece by placing a weld fixture over the end cap and the second open end of the thin-walled tube and applying energy to the junction thereof
Data Source
AI summary
Methods of manufacturing and fixtures for manufacturing containers, particularly for holding cosmetic products, using thin-walled tubes. One end of a container may be formed using an integral process, such as insert molding, while the other end of the container is formed using assembly steps, such as welding, to form a completed cosmetics container from a thin-walled tube.