Paper Overcap With Expandable Bead for Reclosable Sealing
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Solution Overview
Problem
Existing paper-based overcaps face issues with recyclability, lack of a tight fit or seal, wrinkle formation, and complexity in manufacturing, leading to increased costs and manufacturing defects.
Innovation Solution
A one-piece paper-based overcap with a circumferential bead that expands and retracts to maintain a seal, made from a single paper-based material, allowing for recyclability and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic overcaps are used to provide a tight seal and repeated reclosures, then sealing performance is improved, but recyclability deteriorates because plastic polymers are not readily recyclable in common streams
Solution Approach 1:
The patent changes the material parameter from plastic polymer to paper-based material, transforming the overcap from non-recyclable to recyclable in curbside streams while maintaining functional performance through design innovations
Solution Approach 2:
The patent uses composite paper-based materials with specific properties (stretchability, recovery) to achieve both recyclability and sealing performance, combining multiple material characteristics in a single paper-based structure
2Productivity
If deep draw process is used to manufacture paper overcaps, then production capability is improved, but wrinkle formation increases on the skirt which limits printing and labeling applications
Solution Approach 1:
The patent modifies the physical parameters of the paper material (stretchability, recovery properties) to accommodate the deep draw process while minimizing wrinkle formation, enabling high-volume production of smooth-skirted overcaps
Solution Approach 2:
The patent employs curved/spheroidal forming in the deep draw process to transform flat paper blanks into three-dimensional overcaps with smooth skirts, using controlled radial and tangential stresses to achieve desired shape with minimal defects
3Object-generated harmful factors
If existing paper overcap designs are used, then recyclability is improved, but tight fit and seal capability deteriorate with repeated use due to natural expansion of paper composition
Solution Approach 1:
The patent incorporates dynamic properties into the paper overcap design, allowing the material to stretch and conform during application and reclosure while maintaining consistent seal pressure through controlled elastic recovery
Solution Approach 2:
The patent modifies key material parameters including stretchability (10-50% elongation), recovery rate (70-90% rebound), and thickness (0.5-2.0mm) to achieve both recyclability and reliable tight fit across multiple reclosures
4Strength
If multi-component paper overcaps with adhesives are used, then structural integrity is improved, but manufacturing complexity increases and recyclability deteriorates due to non-recyclable adhesives
Solution Approach 1:
The patent merges multiple functions into a single monocomponent paper-based structure, eliminating the need for separate components and adhesives, thereby simplifying manufacturing and ensuring full recyclability while maintaining structural integrity
Solution Approach 2:
The patent uses homogeneous monocomponent paper-based material throughout the entire overcap structure, avoiding composite materials with non-recyclable components and enabling straightforward recycling in curbside streams
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 tight seal with repeated use, reduces manufacturing complexity and costs, and minimizes wrinkle formation, while being recyclable in curbside streams.
Implementation Method 1
the circumferential bead is configured to flex, at least partially, radially outward when the overcap is placed over the container and radially inward when the overcap is removed from 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.