Perforated Packaging Cap Structure for Low-Pressure Injection Molding
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Solution Overview
Problem
Existing packaging lids face challenges in reducing weight while maintaining functionality, avoiding manufacturing issues, and minimizing environmental impact, particularly in injection molding processes.
Innovation Solution
A packaging lid design featuring a perforated upper wall with radial arms and a central portion, allowing for reduced material usage and injection pressure, while ensuring effective sealing and manufacturing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of the upper wall is reduced to lighten the weight of the cap, then the weight is reduced, but the injection pressure increases significantly
Solution Approach 1:
The upper wall is divided into multiple segments (walls separating compartments) with strategic openings, rather than a solid continuous structure. This segmentation reduces material usage and weight while maintaining structural integrity and controlling injection flow patterns to manage pressure levels.
Solution Approach 2:
The upper wall incorporates openings and a perforated central portion that create a controlled porous structure. This allows the injection mold to fill more evenly without requiring excessive pressure, while still providing sufficient structural support and reducing overall material consumption.
2Weight of moving object
If the thickness of the upper wall is reduced to reduce weight, then the weight is reduced, but manufacturing quality deteriorates due to air trapping in the mould
Solution Approach 1:
The upper wall is segmented into multiple compartments with strategic openings that act as air escape pathways during injection molding. This prevents air trapping and manufacturing defects while using less material, thus reducing weight without compromising quality.
Solution Approach 2:
The openings in the upper wall serve as intermediary channels that facilitate the escape of trapped air during the injection process. This intermediary structure prevents air pockets from forming in the final product, maintaining manufacturing quality despite reduced wall thickness.
3Weight of moving object
If the thickness of the upper wall is reduced to reduce weight, then the weight is reduced, but energy consumption increases
Solution Approach 1:
The segmented upper wall structure with openings reduces the total material required, directly reducing weight. The segmentation also optimizes the injection molding process by creating natural flow paths, reducing the energy required for injection and overall manufacturing energy consumption.
4Weight of moving object
If the thickness of the upper wall is reduced to reduce weight, then the weight is reduced, but existing manufacturing installations may require re-engineering
Solution Approach 1:
The design modifies geometric parameters (wall thickness, opening sizes, compartment configurations) within ranges that are compatible with existing injection molding capabilities. By carefully selecting parameters that stay within standard manufacturing tolerances and process ranges, the design achieves weight reduction without requiring re-engineering of existing installations.
Data Source
AI summary
Device (1) for packaging a product, comprising:a container (2),a closure lid (3),a seal (70),the lid (3) comprising:a cover (10),a cap (20), fixed inside the cover, and comprising:a mounting skirt (21),a perforated upper wall (22), comprisinga peripheral annular portion (25) connecting to the mounting skirt (21),a central portion (23),at least five arms (24) connecting the central portion (23) to the annular portion (25) and leaving apertures (26) between them, these arms in cross section having a shape factor, defined by the ratio L/e, where L denotes the width of the arm and e the thickness thereof, of between 1 and 2.