Crimp Cap Foil Plastic Coating Edge Coverage
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Solution Overview
Problem
Existing methods for producing flanged caps from metallic foil layers with plastic coatings face challenges in avoiding particle formation and ensuring a secure, particle-free handling process, especially in pharmaceutical applications.
Innovation Solution
A method involving a coated metallic foil layer with a transparent plastic layer and a lacquer layer, where the plastic layer is stretched to cover the cut edge of the foil layer during deep-drawing, and an adhesive with a color effect is used to connect the plastic layer to the metallic foil, reducing particle risk and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plastic-coated metallic foil layer is used as starting material for crimp cap production, then manufacturing efficiency is improved and particle formation risk is reduced, but the cut edges of the foil layer remain exposed and uncovered by the plastic layer
Solution Approach 1:
The plastic layer is applied to the metallic foil layer before the deep drawing process, so that the plastic coating is already in place during cutting and forming operations. This preliminary coating prevents particle formation during manufacturing while the plastic layer is subsequently stretched to cover the cut edges after forming
Solution Approach 2:
The plastic layer is designed to be dynamically stretched during and after the deep drawing process. The plastic layer initially covers the foil layer, then is stretched to conform to the formed crimp cap shape and extend beyond the cut edges, adapting its position to different manufacturing stages
2Shape
If a transparent plastic layer is used to determine color appearance, then aesthetic quality is improved, but the plastic layer must be bonded securely to prevent particle separation
Solution Approach 1:
The invention uses a composite structure with a metallic foil layer bonded to a transparent plastic layer. The metallic foil provides structural integrity while the transparent plastic layer provides color appearance and protective functions. The layers are securely bonded to prevent particle separation during handling
Solution Approach 2:
A lacquer layer is introduced as an intermediary between the metallic foil layer and the transparent plastic layer. This lacquer layer facilitates secure bonding between the two layers while allowing the transparent plastic layer to maintain its color-determining function
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 significantly reduces the risk of particle separation during handling and manufacturing of flanged caps for pharmaceutical containers, utilizing existing coated materials and ensuring a secure, efficient production process.
Implementation Method 1
the plastic layer is stretched to cover the cut edge of the foil layer during deep-drawing
Implementation Method 2
an adhesive with a color effect is used to connect the plastic layer to the metallic foil
Data Source
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AI summary
The invention relates firstly to a method for producing a crimp cap for a container for receiving a pharmaceutical substance, in particular an ampoule, wherein the crimp cap has a metal foil layer, which is covered over at least on the outside with a layer of plastic forming a covering of the foil layer. In order to provide an advantageous method for producing a crimp cap from a metal foil layer with a layer of plastic forming a covering of the foil layer, while avoiding the risk of particle formation as much as possible, it is proposed that a material strip M having an already plastic-covered foil layer is formed into the crimp cap by punching out and deep drawing. The invention also relates to a crimp cap for a container for receiving a pharmaceutical substance, and also to a container with a pharmaceutical substance.