Fiber-Based Packaging Opening Device Injection Molding
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Solution Overview
Problem
Existing opening devices for pourable food packages, such as Tetra Brik Aseptic and Tetra Fino Aseptic, are inefficient in terms of material usage and production time, particularly in high-volume, low-cost packaging scenarios, where they can hamper production speed and increase costs.
Innovation Solution
A method of manufacturing an opening device by arranging mold halves with overlapping cavities on a fibre-based packaging laminate, injecting a melt to penetrate and fill both cavities, creating a connected opening device that transfers pulling forces to pushing forces within the laminate, reducing delamination risks and allowing for efficient material usage and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional opening devices are used for high-volume, low-cost packages, then opening functionality is achieved, but production speed is hampered and costs increase
Solution Approach 1:
The opening device is merged directly with the packaging laminate by injection molding the device into the laminate material itself, creating an integrated structure that eliminates separate components and reduces production steps while maintaining opening functionality
Solution Approach 2:
The opening device is extracted as a separate injection-molded component that can be independently manufactured and then applied to the packaging laminate, allowing for optimized production of the device itself without complicating the packaging process
2Loss of substance
If conventional opening devices are used, then opening functionality is provided, but material usage efficiency decreases and production time increases
Solution Approach 1:
The opening device structure is merged with the packaging laminate through direct injection molding, eliminating the need for additional materials and assembly steps, thereby improving material efficiency and reducing production time
Solution Approach 2:
The opening device is pre-formed through injection molding with the packaging laminate during the packaging production process itself, rather than being added as a separate post-processing step, which reduces overall production time
3Reliability
If mold cavities are arranged with overlap for penetration molding, then a connected opening device is created with improved force transfer, but manufacturing precision requirements increase
Solution Approach 1:
The injection process itself creates the precise alignment and connection between overlapping mold cavities through the natural flow and pressure of the injected material, which automatically forms the bridging section that connects the two portions of the opening device
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 enables time and material-efficient production of opening devices, ensuring a reliable and leak-proof opening mechanism while minimizing the risk of delamination and moisture absorption, and allows for visually appealing and functionally complex designs with reduced polymer material usage.
Implementation Method 1
injecting a melt into at least said first mold cavity, wherein the melt, due to pressure being built up in said cavity, penetrates through the fibre based packaging laminate in an overlapping area and fills also at least said second mold cavity
Data Source
AI summary
The present invention relates to an opening device comprising a first portion on one side of a fibre based packaging laminate and a second portion on an opposite side of the fibre based packaging laminate, the first and second portion being formed in one and the same piece and joined by at least one material bridge extending through the packaging laminate. The present invention also relates to a method for manufacturing the opening device and to a packaging material to be used is such a method.