PET Closure Attachment via Deformation and Ultrasonic Welding
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Solution Overview
Problem
The existing assembly processes for packaging closure elements, such as screw threads or clipping mechanisms, are inefficient and unreliable for attaching closures to containers made of polyethylene terephthalate (PET) or polyethylene naphthalate (PEN), requiring a more reliable and efficient method for creating a permanent attachment.
Innovation Solution
A process involving the deformation of attachment means on the container and closure, such as a groove and ridge, through punching or rolling, combined with ultrasonic welding, to create a permanent and fluid-tight connection between the container and closure, utilizing materials like PET, PEN, or their combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw threads or clipping mechanisms are used to attach closure to container, then the assembly process is simple, but the attachment reliability is insufficient
Solution Approach 1:
The patent combines punching/rolling deformation with ultrasonic welding to create a hybrid attachment system. The punching/rolling creates interlocking deformation between the closure ridge and container groove, while ultrasonic welding provides additional molecular-level bonding, together achieving high attachment reliability that neither method could achieve alone.
Solution Approach 2:
The patent replaces traditional mechanical attachment systems (screw threads, clipping mechanisms) with a deformation-based attachment system. Instead of using threaded fasteners or clips, the closure ridge is permanently deformed into the container groove through punching or rolling, creating a mechanical interlock that is more reliable than traditional mechanical systems.
2Reliability
If punching or rolling deformation is applied to create permanent attachment, then the attachment reliability is improved, but the risk of material cracking or whitening increases
Solution Approach 1:
The patent combines punching/rolling deformation with ultrasonic welding to create a hybrid attachment system. The punching/rolling creates interlocking deformation between the closure ridge and container groove, while ultrasonic welding provides additional molecular-level bonding, together achieving high attachment reliability that neither method could achieve alone.
Solution Approach 2:
The patent controls the deformation parameters (punching force, rolling pressure, temperature) to remain within safe limits that achieve permanent deformation without exceeding the material's elastic limit and causing cracking or whitening. The process parameters are optimized to balance deformation effectiveness with material integrity.
3Reliability
If ultrasonic welding is used in combination with permanent deformation, then the fluid-tight connection is improved, but the energy consumption increases
Solution Approach 1:
The patent combines punching/rolling deformation with ultrasonic welding to create a hybrid attachment system. The punching/rolling creates interlocking deformation between the closure ridge and container groove, while ultrasonic welding provides additional molecular-level bonding, together achieving high attachment reliability that neither method could achieve alone.
Solution Approach 2:
The patent uses a combination of punching/rolling and ultrasonic welding where each method performs a partial function. The punching/rolling provides the primary mechanical interlock, while ultrasonic welding adds a secondary bonding layer, ensuring fluid-tight connection without applying excessive energy that would be wasted.
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
This method ensures a reliable and efficient attachment of the closure to the container, preventing leakage and providing a tamper-evident mechanism, while minimizing stress on the plastic material to avoid cracking or whitening, and can be performed within a temperature range that maintains the material's integrity.
Implementation Method 1
deforming at least one of the first and/or second attachment means up to the point of permanent deformation of the PET, PEN, PETG, PTT, PLA, PHAs or other materials with according stiffness properties
Implementation Method 2
the process further comprises ultrasonic welding of the first and second attachment means, in addition to the permanent deformation of said first and/or second attachment means
Data Source
AI summary
The present invention is directed to process for making a packaging, said packaging comprising a container (2) with a container body (5) and a container opening having an upper edge, said packaging further comprising a closure (4) for closing said container, the container and the closure being made out of polyethylene terephtalate (PET), polyethylene naphtalate (PEN), or a combination thereof, said container (2) and said closure (4) comprising respectively first (8) and second (9) attachment means, characterized in that: said process comprising the steps of in order: (i) fitting said first (8) and second (9) attachment means to each other, (ii) deforming at least one of the first and/or second attachment means up to the point of permanent deformation of the PET or PEN material, by punching, rolling, or a combination thereof, so as to create a permanent, leak-tight, attachment between said container and said closure.