One-Piece Paper Overcap With Expandable Bead Sealing
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Solution Overview
Problem
Existing paper overcaps face issues with recyclability, lack of a tight fit or seal, multiple components leading to manufacturing complexity and cost, and visible wrinkles, which affect their aesthetic appeal and recyclability.
Innovation Solution
A one-piece paper-based overcap with a circumferential bead that expands and retracts to maintain a seal, made from a single piece of paper with elastic properties, allowing for recyclability and a tight fit even with multiple reseals, while reducing manufacturing complexity and wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic overcap is used, then a tight seal and repeated reclosures are achieved, but recyclability is compromised due to non-recyclable polymers
Solution Approach 1:
The patent changes the material parameter from plastic polymer to elastomeric material with specific properties (elongation 100-500%, resilience 40-90%). This material parameter change enables both recyclability (unlike plastic) and tight sealing through elastic deformation and recovery, resolving the contradiction between seal reliability and recyclability
Solution Approach 2:
The overcap uses a composite structure combining paperboard (for rigidity and recyclability) with an elastomeric material (for sealing and recovery). This composite approach allows the paper component to be recyclable while the elastomeric component provides the tight seal function, resolving the contradiction between these two requirements
2Adaptability or versatility
If multiple paper components are adhered together, then overcap functionality is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the sealing function and the structural function into a single integrated elastomeric component rather than using separate paper components adhered together. This single-piece construction eliminates adhesives, reduces manufacturing steps, and lowers complexity while maintaining full overcap functionality including sealing, reclosure, and structural support
3Ease of manufacture
If deep draw process is used for paper overcap, then manufacturing is simplified, but visible wrinkles appear on the skirt
Solution Approach 1:
The patent uses an elastomeric material with high elongation properties (100-500%) that can be formed into a flexible skirt that conforms to the container opening. This flexible material can be manufactured using simplified processes without creating permanent visible wrinkles, as the elastomeric nature allows the material to smooth out during forming and maintain a clean appearance
4Object-generated harmful factors
If natural expansion of paper composition is allowed, then recyclability is maintained, but overcap becomes loose during repeated use
Solution Approach 1:
The patent changes the material from conventional paper to an elastomeric material with specific physical parameters (elongation 100-500%, resilience 40-90%). This parameter change enables the material to expand and contract elastically during repeated reclosures while maintaining a tight fit, and remains compatible with recyclable paper-based container systems
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
The overcap provides a recyclable, aesthetically pleasing solution with a tight seal that maintains its fit through multiple reseals, reducing manufacturing costs and complexity, and minimizing visible wrinkles.
Implementation Method 1
The circumferential bead is configured to expand and retract radially
Implementation Method 2
The protrusion may be configured to create friction against a rim of the container
Data Source
AI summary
A one-piece paper lid and container system using the one-piece paper lid is provided herein. The one-piece paper lid comprises base having a central portion and peripheral portion, and a circumferential bead disposed adjacent the peripheral portion of the base. The circumferential bead is radially extendable between an inward position defining a first inner diameter and an outward position defining a second inner diameter. The one-piece paper lid further comprises a skirt extending downward from the circumferential bead. The skirt comprises an outer sidewall, an inner sidewall and an upwardly extending curl connecting the outer sidewall and the inner sidewall, wherein the inner sidewall comprises an inner protrusion extending radially inward.