Hybrid Resealable Container With Cardboard Tamper-Evident Flap
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Solution Overview
Problem
Conventional cardboard containers cannot be effectively resealed after initial opening, leading to exposure of contents to the environment, which affects product freshness, and lack tamper evidence features to determine if the container has been opened.
Innovation Solution
A composite container design featuring a bottom film layer, a top film layer with a resealable flap and pull tab, and a cardboard layer with a perforated pull tab, allowing for resealing without compromising the container's integrity and providing tamper evidence through the cardboard layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cardboard containers are used, then the container structure is simple and inexpensive, but the container cannot be effectively resealed after initial opening and lacks tamper evidence features
Solution Approach 1:
The patent applies composite materials by combining a cardboard layer with a flexible film layer (comprising adhesive layers and barrier layers) to create a hybrid container structure. The cardboard provides structural integrity while the film layer enables resealability through adhesive properties and flexibility, resolving the contradiction between simple structure and resealable operation.
Solution Approach 2:
The container is segmented into distinct functional layers: a cardboard layer for structural support, adhesive layers for bonding and resealing, and barrier layers for protection. This segmentation allows each layer to perform its specific function optimally, enabling resealability without compromising the overall structural integrity of the container.
2Ease of operation
If the top film layer is fully adhered to the bottom film layer, then the container structure is strong and sealed, but the container cannot be opened and resealed
Solution Approach 1:
The adhesive layer exhibits local quality variations with different adhesive strengths in different regions. The first portion has strong adhesive properties for initial sealing, while the second portion has reduced adhesive properties enabling easy opening and resealing. This local differentiation resolves the contradiction between maintaining strong bonds and enabling operational flexibility.
Solution Approach 2:
The adhesive layer transitions from a static strong bond to a dynamic system that allows controlled opening and resealing. The varying adhesive properties enable the container to adapt between sealed and open states, providing both structural strength and operational flexibility throughout the product lifecycle.
3Ease of operation
If the film layer is made thin and flexible for resealing, then the container is easy to reseal, but the film layer tears easily during use
Solution Approach 1:
The film layer is constructed as a composite structure with multiple layers including adhesive layers and barrier layers. This composite construction provides the necessary flexibility for resealing while the layered structure and adhesive bonding to cardboard prevent tearing during use, resolving the contradiction between flexibility and durability.
Solution Approach 2:
The patent utilizes flexible thin films with engineered properties that balance flexibility and strength. The film is thin enough to be flexible and easily resealable, yet its composite construction and adhesive bonding provide sufficient durability to prevent tearing during normal handling and use.
4Reliability
If a cardboard pull tab is added for tamper evidence, then tamper evidence capability is provided, but the container structure becomes more complex
Solution Approach 1:
The cardboard layer serves multiple functions: it provides structural support for the container, acts as a substrate for the adhesive and barrier layers, and functions as a tamper-evident pull tab. This multi-functionality reduces the need for additional separate components, thereby minimizing structural complexity while achieving tamper evidence capability.
Solution Approach 2:
The tamper evidence feature is merged with the structural cardboard layer rather than being a separate component. The cardboard pull tab is integrated into the container wall structure, combining structural support and tamper evidence functions into a single element, thus avoiding increased device complexity.
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
Enables repeated opening and resealing of the container, maintaining product freshness and providing visual tamper evidence without tearing issues in the film layer.
Implementation Method 1
The top film layer is partially adhered on its lower surface to the upper surface of the bottom film layer via an adhesive layer which comprises at least one resealable adhesive zone, at least one permanent adhesive zone
Data Source
AI summary
The present invention relates to a composite container comprising a bottom film layer and a top film layer at least partially adhered to the bottom film layer. The top film layer is scored to form at least one resealable flap and at least one pull tab which is not adhered to the bottom film layer. The bottom film layer comprises at least one cavity opening. A cardboard layer is adhered on its lower surface to the upper surface of the top film layer, wherein the cardboard layer has at least one cavity opening which is substantially aligned with the scoring of the top film layer resealable flap and the cardboard layer is perforated to define a perimeter of at least one pull tab which is substantially aligned with and adhered, on its underside, to the upper surface of the top film layer pull tab.