Disposable Container Center Welding via Flat-Bottom Film Structure
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Solution Overview
Problem
The manufacturing of gusseted disposable containers faces challenges such as misalignment of gusseted film plies leading to stress points and leakage issues, and the inability to form weldments at the center or centroid positions due to interference from edge welds, limiting their use in pharmaceutical applications like mixers and bioreactors.
Innovation Solution
A method of forming disposable containers from weldable plastic film using specific patterns and folding lines to create polygonal sections and quadrilateral sections, allowing for welding at various positions, including the center, and forming openings for additional functionality, without the need for gusseted film plies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If gusseted film plies are used to form disposable containers, then the containers can fit square and rectangular bins or tanks, but misalignment of gusset folds occurs leading to stress points and leakage
Solution Approach 1:
The patent removes the gusseted film plies entirely from the container structure. Instead of using traditional gusseted construction that requires inward folds and edge welds, the invention uses a flat-bottomed bag structure made from a single continuous film ply that is heat sealed along its edges to form vertical side walls, eliminating the gusset folds that cause misalignment and leakage problems
Solution Approach 2:
Rather than folding the film inward to create gussets and then welding edges, the invention inverts the approach by welding the film edges first to form vertical side walls, then creating the flat bottom by folding and welding the base sections. This reversal of the manufacturing sequence eliminates the alignment problems inherent in traditional gusseted construction
2Ease of manufacture
If gusseted film plies are used, then containers can be manufactured with folded sides, but weldments cannot be formed at center or centroid positions due to interference from edge welds
Solution Approach 1:
The patent segments the container into distinct functional zones: vertical side walls formed by edge welds, and a separate flat bottom section formed by folding and welding the base. This segmentation allows weldments to be positioned independently at the center of the bottom or side walls without interference from edge welds, enabling versatile configurations for mixers, bioreactors, and other pharmaceutical applications
3Ease of manufacture
If gusset folds are introduced into film plies, then containers can be formed, but stress points and fatigue cracking occur during routine use
Solution Approach 1:
The invention extracts and eliminates the gusset fold structure entirely from the container design. By using a flat-bottomed bag construction with vertical side walls formed from a single continuous film ply, the design removes the stress concentration points that occur at gusset folds, resulting in enhanced structural integrity and resistance to fatigue cracking during routine pharmaceutical handling operations
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 minimizes leakage points along edge welds, enables weldments at desired positions, and facilitates the use of disposable containers as mixers and bioreactors by enhancing their structural integrity and versatility.
Implementation Method 1
heat sealing the plastic film along its edges to form vertical side walls
Implementation Method 2
folding the plastic film along predetermined folding lines extending between the opposite edges
Data Source
AI summary
A polyhedron disposable container formed from flexible weldable plastic film is provided. The container has opposite ends and an opening that accommodates a port at the center of at least one of such ends. The container also has multiple sides and an opening on at least one such side located midway between the edges of such side.