Laminated Packaging Material for Injection-Molded Opening Devices
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Solution Overview
Problem
Existing packaging materials require pre-manufactured opening devices, which complicate the packaging process and may not ensure the integrity of the packaging container while maintaining a well-defined opening force or tearing force.
Innovation Solution
A laminated packaging material with longitudinally distributed holes extending through its thickness, allowing for injection molding of opening devices directly onto the material, ensuring precise positioning and integration with existing machinery for high throughput production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-manufactured opening devices are attached to packaging material, then the packaging container can be opened, but the process becomes complicated and integrity may not be ensured
Solution Approach 1:
The opening device is integrated directly into the packaging material structure through injection molding, merging the opening function with the packaging container itself. This eliminates the need for separate attachment processes and reduces overall system complexity while maintaining opening capability.
Solution Approach 2:
The opening device is pre-formed through injection molding during the packaging material manufacturing process, rather than being attached later. This preliminary action simplifies the overall packaging process by combining multiple steps into one integrated manufacturing flow.
2Ease of operation
If pre-manufactured opening devices are attached to packaging material, then opening function is provided, but positioning precision and integration with machinery are compromised
Solution Approach 1:
Holes are pre-formed in the packaging material at precisely controlled positions during the injection molding process. This preliminary positioning action ensures accurate placement of opening devices relative to crease lines and other structural features, achieving high manufacturing precision.
Solution Approach 2:
The mechanical attachment process is replaced by direct injection molding integration. This substitution eliminates positioning errors associated with mechanical attachment methods and ensures precise, repeatable placement of opening devices during the molding process itself.
3Ease of operation
If holes are punched in bulk layer prior to lamination, then opening devices can be attached, but the packaging material integrity is compromised
Solution Approach 1:
Holes are pre-formed in the bulk layer before lamination, but the critical innovation is that these holes are subsequently sealed by the lamination process. This preliminary action creates openings for future device attachment while the lamination restores and maintains packaging integrity.
Solution Approach 2:
The lamination layers act as an intermediary that seals the punched holes, temporarily closing the openings to maintain packaging integrity. This intermediary action allows the packaging material to remain intact during storage and transport, with openings only created when opening devices are later attached.
4Productivity
If high speed packaging machines are used, then productivity increases, but the complexity of integrating opening devices increases
Solution Approach 1:
Opening devices are pre-formed and integrated into the packaging material during its manufacturing process, before it reaches the high-speed packaging machine. This preliminary action eliminates the need for complex real-time integration operations during high-speed packaging, maintaining both productivity and simplicity.
Solution Approach 2:
The opening device manufacturing is merged with the packaging material production process through injection molding. This consolidation creates a single integrated component that can be processed at high speeds without requiring separate, complex integration steps in the packaging machinery.
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 efficient production of packaging containers with integrated opening devices that maintain container integrity and define the opening force, suitable for aseptic packaging of liquid foods.
Implementation Method 1
laminating one or more outside layers to the bulk layer, said outside layers intended to face the exterior of a packaging container formed by the packaging material, iv) laminating one or more inside layers to the bulk layer
Implementation Method 2
both of the longitudinal edges of the web being united to each other in an overlap joint by welding together the inner- and outermost heat sealable thermoplastic polymer layers
Implementation Method 3
one open end is closed off by means of folding and heat-sealing of integral end panels
Data Source
Figure 1
Figure 2~3a
Figure 3b~4
AI summary
A laminated packaging material (10) is provided. The laminated packaging material (10) comprises a bulk layer (12) of paper or paperboard or other cellulose-based material comprising a plurality of longitudinally distributed holes extending through the bulk layer (12), one or more outside layers (14) being laminated to the bulk layer (12), one or more inside layers (16, 18, 19) being laminated to the bulk layer (12), wherein said inside and outside layers (14, 16, 18, 19) covering said holes on the bulk layer and so form the plurality of longitudinally distributed laminated holes (30), and a plurality of longitudinally distributed primary holes (31) extending through the entire thickness of the of the associated laminated hole and wherein the each primary hole (31) is surrounded by the edges of the laminated hole (30).