Laminated Roll Delamination for Recloseable Container Manufacturing
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Solution Overview
Problem
Conventional container manufacturing processes require separate web feeds for the first and second portions, limiting the ability to use different materials and eliminating the need for inter-portion hinges and joints, especially for recloseable designs.
Innovation Solution
A method utilizing a laminated roll with a first layer, a second layer, and an adhesive layer to delaminate, form, and relaminate the first layer for the container's first portion and the second layer for the second portion, allowing for a single web feed and enabling different material usage without inter-portion hinges or joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate web feeds are used for the first and second portions, then the manufacturing process can accommodate different materials for base and lid portions, but the device complexity and process difficulty increase
Solution Approach 1:
The patent combines multiple web feeds into a single integrated web feed system that supplies both the first layer (base portion) and second layer (lid portion) materials simultaneously. This merging eliminates the complexity of coordinating separate web feeds while maintaining the ability to use different materials, as the single web feed is configured to deliver layered materials in a coordinated manner.
Solution Approach 2:
The single web feed system is designed to perform multiple functions: it feeds both the base portion material and lid portion material, provides material alignment, and enables continuous production. This multi-functional design replaces what would otherwise require separate dedicated web feed systems for each portion.
2Productivity
If a single web feed is used, then the manufacturing efficiency improves, but the ability to use different materials for base and lid portions is limited
Solution Approach 1:
The patent employs composite material structures where the first layer and second layer can be made of different materials that are bonded together. The single web feed system is configured to supply these different materials in a layered configuration, enabling the use of composite materials while maintaining manufacturing efficiency through continuous single-feed operation.
Solution Approach 2:
The web feed system segments the material supply into distinct layers (first layer for base, second layer for lid) that are fed simultaneously through a single integrated system. This segmentation allows different materials to be supplied through the same web feed mechanism while maintaining their individual properties and enabling post-forming separation or bonding as needed.
3Ease of operation
If inter-portion hinges and joints are included, then the container can be recloseable, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent removes the need for inter-portion hinges and joints by extracting this function entirely from the design. Instead of adding mechanical fastening components, the container uses an adhesive bonding system where the lid is adhesively bonded to the base, eliminating complex moving parts while maintaining recloseability through adhesive repositioning.
Solution Approach 2:
The patent replaces the mechanical hinge and joint system with an adhesive bonding system. Instead of using mechanical inter-portion joints that require complex assembly and disassembly mechanisms, the adhesive system provides a simpler chemical bonding approach that enables recloseability without mechanical complexity.
4Device complexity
If adhesive bonding is used instead of mechanical joints, then the manufacturing process is simplified, but the structural integrity may be compromised
Solution Approach 1:
The patent optimizes adhesive bonding parameters including adhesive composition, bonding surface preparation, bonding pressure, and curing conditions to ensure that the adhesive bond strength meets or exceeds the requirements for structural integrity. By carefully controlling these parameters, the adhesive system achieves strength comparable to or greater than mechanical joints while maintaining manufacturing simplicity.
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 recloseable containers with base/lid portions made from different materials using a single web feed, improving manufacturing efficiency and flexibility while maintaining structural integrity and convenience.
Implementation Method 1
a laminated roll (comprising a first layer, a second layer and an adhesive layer therebetween)
Implementation Method 2
delaminating the first layer from the second layer
Implementation Method 3
forming (e.g., thermoforming) receptacles in the delaminated first layer
Implementation Method 4
relaminating the second layer with the formed first layer
Data Source
AI summary
A method and apparatus (128) for making a plurality of containers (100) from a laminated roll (130) comprising a first layer of thermoformable material (132), a second layer of material (134), and an adhesive layer (136) therebetween. The apparatus (128) comprises a feeding station (142) for the laminated roll (130), a delaminating station (144) whereat the first layer (132) is delaminated from the second layer (134), a thermoforming station (146) whereat receptacles (104) are formed in the delaminated first layer (132), and a relaminating station (150) whereat the second layer (134) is relaminated with the thermoformed first layer (132).