Flexible-Stop Cap Tray for Low-Force Vial Sealing
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Solution Overview
Problem
Existing packaging trays for caps used to seal vials face issues such as significant force requirements for cap detachment, potential damage to the tray due to excessive deflection, and poor clipping due to dimensional variations, especially in height differences between caps and bottles.
Innovation Solution
A packaging tray design featuring flexible bridges connecting stops to a base, allowing perpendicular movement, and flexible tabs for easy cap detachment, with optional shock-absorbing elements and spacers to accommodate dimensional variations, facilitating reliable cap attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple rods are used to push caps downwards for detachment, then cap separation is achieved, but significant force is required causing tray damage due to excessive deflection
Solution Approach 1:
The stops are made movable rather than fixed, allowing them to deflect elastically during cap detachment. This dynamic design absorbs the detachment force through controlled deformation of the flexible bridges, preventing force transmission to the tray base that would cause damage.
Solution Approach 2:
Flexible bridges connect the stops to the base, providing a compliant connection that allows the stops to move perpendicular to the main plane. These flexible elements absorb mechanical stress during cap detachment while maintaining structural integrity, eliminating the need for excessive force.
2Stability of the object's composition
If caps are held rigidly on the tray, then stable positioning is achieved, but poor clipping occurs due to excessive dimensional variations in height
Solution Approach 1:
The stops are designed to move vertically along the z-axis while maintaining horizontal positioning. This dynamic capability allows the stops to adapt to height variations in caps and bottles, ensuring reliable clipping despite dimensional tolerances while maintaining stable positioning during transport.
Solution Approach 2:
The system allows vertical displacement of stops to accommodate variations in cap and bottle heights. By changing the vertical position parameter of the stops, the system adapts to dimensional variations and ensures proper engagement between caps and bottles.
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
The tray design enables efficient, damage-free cap detachment and reliable attachment to bottles, accommodating variations in dimensions, and allows for easy, tool-free simultaneous cap separation without damaging the tray.
Implementation Method 1
each stop is connected to the base by flexible bridges, allowing movement of said stop, perpendicular to the main plane
Implementation Method 2
at least one stop includes a shock-absorbing element, intended to be located against the cap
Data Source
Figure 1a~1b
Figure 1c~2a
Figure 2b~2c
AI summary
The invention relates to a packaging tray (100) for caps comprising: - a base (110) having a general plate shape, an upper face and a lower face (112) extending along a principal plane (x,y), - a plurality of stops (120), each stop (120) being intended to be in contact with a cap when a plurality of caps are held against the lower face (112) of the base (110), - a plurality of fastening systems (130), each fastening system (130) being associated with a stop (120) and configured to hold a cap against said stop (120). The packaging tray (100) is notable in that each stop (120) is connected to the base (110) by flexible bridges (125), allowing movement of said stop (110) perpendicular to the principal plane (x,y).