Direct Bonded Can Lid with Multilayer Aluminum Seal
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Solution Overview
Problem
Existing metal packaging for foodstuffs requires an intermediate metal ring to support the lidding material, leading to material wastage, increased manufacturing time, and reduced access to the can contents, as the lid is not bonded directly to the can body.
Innovation Solution
A can design where the lid is directly bonded to the metal can body using a multilayer lidding material with an aluminum layer and a polypropylene bond layer, with an optional integral tab and an inclined sealing surface to facilitate easier opening and improved seal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an intermediate metal ring is used to support the lidding material, then seal integrity is improved, but material wastage increases and manufacturing time increases
Solution Approach 1:
The invention extracts and eliminates the intermediate metal ring from the packaging structure. Instead of using a separate ring to support the lidding material, the lid is bonded directly to the can body, removing the unnecessary component that causes material wastage while maintaining seal integrity through direct bonding.
Solution Approach 2:
The invention merges the functions of the can body, intermediate ring, and lidding material into a direct bond between the can body and lidding material. This consolidation eliminates the need for the separate metal ring component, reducing material usage while achieving the same sealing function through the bonded connection.
2Reliability
If an intermediate metal ring is used to support the lidding material, then seal integrity is improved, but manufacturing time increases
Solution Approach 1:
The invention combines the steps of ring manufacturing and lidding material attachment into a single direct bonding operation. By eliminating the intermediate ring, the manufacturing process requires fewer discrete steps and less handling time while achieving the same sealing reliability through direct bonding of the lidding material to the can body.
Solution Approach 2:
The invention removes the intermediate metal ring from the manufacturing process, eliminating the time required for ring production, handling, and assembly. This extraction of the unnecessary component streamlines the manufacturing workflow while maintaining seal integrity through the direct bond.
3Reliability
If an intermediate metal ring is used to support the lidding material, then seal integrity is improved, but access to can contents is reduced
Solution Approach 1:
The invention extracts the intermediate metal ring that obstructs access to the can contents. By bonding the lidding material directly to the can body without a protruding ring, the opening surface is maximized and access to the contents is improved while seal integrity is maintained through the direct bonding connection.
4Ease of manufacture
If the lid is bonded directly to the can body, then manufacturing is simplified and material wastage is reduced, but seal integrity may be compromised
Solution Approach 1:
The invention uses a multilayer lidding material structure with an aluminum layer (6-90 microns thickness) and a polypropylene bond layer. This composite structure provides both the necessary bonding capability to the can body and the structural integrity to maintain seal reliability, while simplifying manufacturing by eliminating the intermediate metal ring.
5Ease of manufacture
If a multilayer lidding material with aluminum and polypropylene layers is used, then bonding capability is improved, but material complexity increases
Solution Approach 1:
The invention employs a multilayer lidding material comprising an aluminum layer (6-90 microns thickness) and a polypropylene bond layer. The aluminum layer provides barrier properties and structural integrity, while the polypropylene layer provides bonding capability to the can body. This composite structure achieves effective bonding without requiring complex manufacturing processes or additional components.
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 design simplifies manufacturing, reduces material wastage, enhances access to the can contents, and improves the ease of opening while maintaining or exceeding the burst pressure performance of standard cans.
Implementation Method 1
the lid being fixed directly to the can body; characterized in that the lid is formed of lidding material which comprises a multilayer structure with at least an aluminum layer of from 6 to 90 microns thickness and a bond layer
Implementation Method 2
a multilayer structure with at least an aluminum layer of from 6 to 90 microns thickness
Data Source
AI summary
A can for packaging food, comprising a metal can body and a diaphragm lid (16) formed of lidding material which comprises a multilayer structure with at least an aluminum layer of from 6 to 90 microns thickness and a bond layer for fixing the lid (16) directly to the can body. One method for forming the can forms the lidding material by using an outwardly extending curl (20) at one end of the metal can body as the draw die. Lidding material which is carried by the body maker punch is drawn around the curl of the can body draw die so as to form the lidding material into a cup shape.