Monolithic Tube Assembly With Breakable Cap
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Solution Overview
Problem
Conventional grease tubes or cartridges are prone to damage and leakage during transport and use, and are costly due to their complex assembly requiring multiple parts and labor-intensive manufacturing processes.
Innovation Solution
A monolithic tube assembly with an integrally formed plastic tube and top, featuring a breakable portion and distinct mold release angles for the outer lid and cap pull tab, allowing for a single-piece injection molding that reduces assembly time and risk of damage, while ensuring easy material release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional grease tubes or cartridges are assembled from multiple parts, then they can be manufactured with standard components, but they are prone to damage and leakage during transport and use
Solution Approach 1:
The patent merges multiple separate components (tube, cap, seal, and top assembly) into a single monolithic structure formed by injection molding. This integration eliminates the interfaces between parts that are prone to leakage and damage, while the single-piece construction simplifies manufacturing by eliminating assembly steps.
2Ease of manufacture
If conventional grease tubes use multiple parts and labor-intensive manufacturing, then they can be assembled with standard components, but they are costly to manufacture
Solution Approach 1:
The patent combines multiple manufacturing operations into a single injection molding process that produces the entire tube assembly as one piece. This eliminates the need for separate assembly operations, reducing both labor costs and assembly time while maintaining manufacturing simplicity through a standardized molding process.
Solution Approach 2:
The injection molding process preliminarily forms all structural features, including the tube body, cap, seal engagement features, and top assembly, in a single operation. This preliminary formation of all components eliminates subsequent assembly steps and reduces manufacturing complexity.
3Productivity
If the tube assembly uses a monolithic structure with integrally formed parts, then assembly time and damage risk are reduced, but mold release becomes more difficult
Solution Approach 1:
The patent applies different mold release angle characteristics to different regions of the monolithic structure. Specifically, the tube portion has a greater draft angle relative to the mold parting line than the top portion, allowing the tube to release more easily from the mold while the top maintains its structural integrity. This localized variation in geometry resolves the mold release difficulty without compromising the monolithic structure.
Data Source
AI summary
A tube assembly is disclosed. The tube assembly may include a tube with an outer diameter and an inner diameter. The tube may have a cylindrical shape. The tube assembly may also include a top integrally formed with the tube such that the tube and the top are a monolithic structure. The top may include an outer lid, a cap with a cap pull tab protruding outwards from the tube assembly, and a breakable portion disposed between the cap and the outer lid. The breakable portion may be configured to be relatively structurally weaker than surrounding areas to allow for breaking off and separating completely the cap at the breakable portion.