Flip Cap With Integrated Membrane Seal
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Solution Overview
Problem
Existing reclosable caps for fluid containers require a foil/polyethylene composite seal for shipping, which is costly and needs to be removed by consumers before dispensing, and lack effective sealing and size optimization.
Innovation Solution
A cap design with an annular body and internally threaded sidewall, featuring distinct pour opening portions and a hinge-connected lid with a seal that conforms to the cap's opening, eliminating the need for a foil/polyethylene composite seal, reducing height, and providing enhanced sealing and resealing capabilities without consumer intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a foil/polyethylene composite seal is used beneath the cap during shipping, then sealing capability is improved, but device complexity and cost increase, and the cap must be removed by consumers before dispensing
Solution Approach 1:
The patent removes the foil/polyethylene composite seal from the cap assembly, extracting this component entirely. The sealing function is instead achieved through the cap's own structure - specifically, a flexible membrane integrated into the cap body that forms a seal against the container opening, eliminating the need for separate foil seals and their associated complexity
Solution Approach 2:
The sealing function is merged into the cap body itself through an integrated flexible membrane. This membrane is formed as part of the cap's molded structure and works in conjunction with the rim flange to create the seal, combining what were previously separate components (cap and foil seal) into a single integrated unit
2Reliability
If a foil/polyethylene composite seal is used, then sealing during shipping is improved, but manufacturing cost increases
Solution Approach 1:
The expensive foil/polyethylene composite seal is extracted from the assembly. The replacement integrated membrane seal is formed during the cap molding process itself, eliminating the need for separate foil seal manufacturing and assembly operations, thereby reducing manufacturing cost
Solution Approach 2:
The sealing function is merged into the cap's molded structure, allowing the seal to be produced in the same manufacturing process as the cap body. This integration eliminates additional materials (foil, polyethylene) and assembly steps, reducing overall manufacturing cost while maintaining sealing capability
3Reliability
If the cap includes a foil/polyethylene seal, then sealing is improved, but cap height increases
Solution Approach 1:
The bulky foil/polyethylene composite seal is removed from the cap assembly. The integrated membrane seal is formed within the cap's existing structural thickness, eliminating the need for additional height to accommodate a separate seal layer
Solution Approach 2:
The sealing membrane is merged into the cap's molded structure, utilizing the same material thickness and structural space already allocated for the cap body. This integration eliminates the need for additional height that would be required to accommodate a separate foil seal layer
4Reliability
If consumers must remove the cap to peel off the foil seal, then sealing is maintained, but ease of operation deteriorates
Solution Approach 1:
The foil/polyethylene seal that requires peeling and removal is extracted from the system. The integrated membrane seal remains in place and functional throughout use, allowing consumers to simply lift the flip cap to access contents without any seal removal steps
Solution Approach 2:
The integrated membrane seal is designed to remain in place and continue functioning throughout the product's use. The seal automatically maintains its sealing function when the cap is closed and naturally opens to allow access when the cap is lifted, eliminating the need for consumer intervention to remove or replace seals
Data Source
AI summary
A cap is received on an associated bottle opening. The cap preferably includes an annular body and a sidewall that includes a thread member extending around at least a portion of an inner surface thereof. A closing surface extends substantially perpendicular to the sidewall and is dimensioned to cover the associated bottle opening. As disclosed, an opening in the cap closing surface has first, second, and third portions that each form distinct interconnected narrow, intermediate, and large pour opening portions. A lid is selectively received on the closing surface and includes a seal extending outwardly from a surface thereof. The seal includes similarly dimensioned first, second, and third portions that conform to and selectively seal with the first, second, and third portions of the cap opening. Another exemplary embodiment includes a tear-away panel portion that includes a tab to aid in removal of the panel portion and forming the opening.