Deformable Mould Cup for Solid Formulation Release
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing solid deodorant and antiperspirant formulations often result in the product becoming stuck in the mould, requiring high forces for removal and risking damage to the formulation.
Innovation Solution
A method involving a mould assembly with a deformable cup and skirt, where the skirt is compressed to deform the cup, allowing it to separate from the solid formulation, thereby reducing adhesion and removal forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the solid formulation is formed in a rigid mould, then the manufacturing precision is improved, but the removal force increases and the formulation may be damaged
Solution Approach 1:
The mould is designed with a deformable cup portion that can dynamically change its shape during the manufacturing process. The cup starts rigid to ensure precise formulation formation, then undergoes controlled deformation to release the formulation easily, transforming from a static to a dynamic structure to resolve the contradiction between precision and removal force.
Solution Approach 2:
The mould utilizes materials with changing physical parameters - specifically, the cup is made from a material that undergoes phase change or dimensional change in response to temperature or pressure. This allows the cup to maintain its shape during formulation setting (ensuring precision) then change state to facilitate easy removal (reducing force).
2Productivity
If high forces are applied to remove the solid formulation from the mould, then the removal speed is improved, but the risk of damage to the formulation increases
Solution Approach 1:
The deformable cup allows the mould to adapt its structure during removal, reducing the force needed and enabling faster removal without damaging the formulation. The dynamic deformation creates a larger separation interface that facilitates quick, gentle extraction.
Solution Approach 2:
The cup's deformable structure is pre-configured to cushion and absorb the removal forces, protecting the formulation from damage while maintaining high removal speed. The deformation acts as a buffer that prevents direct transmission of force to the formulation.
3Manufacturing precision
If the cup is made rigid to maintain its shape, then the manufacturing precision is improved, but the formulation may become stuck due to adhesion
Solution Approach 1:
The cup transitions from a rigid state during formulation setting (maintaining precision) to a deformable state during removal (preventing adhesion). This dynamic property change allows the same component to satisfy both the precision requirement and the release requirement at different process stages.
Solution Approach 2:
The cup material's physical parameters (rigidity, elasticity) are changed during the manufacturing process through temperature or pressure control. The cup is rigid at lower temperatures during setting, then becomes more flexible at higher temperatures or under pressure to facilitate easy removal and prevent sticking.
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 significantly reduces the forces required for removing the solid formulation from the mould and minimizes the risk of damage, while also enabling the use of reusable holders for refilling.
Implementation Method 1
the step of deforming then releasing the skirt causes the cup to deform in shape (at least temporarily, depending on the elasticity or plasticity of the cup) which in turn causes the cup (which acts as a mould for the formulation) to separate, at least partially, from the solid formulation
Implementation Method 2
filling the cup with liquid formulation to a predetermined level, determined such that the platform is at least partially submerged in the liquid formulation, and then solidifying the liquid formulation in the cup to form a solid formulation
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A method of manufacturing a solid formulation product comprising steps of: positioning a platform into a cup comprising an open end comprising a skirt, such that the platform is at least partially received by the cup; then filing the cup with liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; solidifying the liquid formulation in the cup to form a solid formulation; once the solid formulation is formed, deforming then releasing the skirt.