Ultrasonic Welding Pour Spout Tamper-Evident Cap
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Solution Overview
Problem
Existing methods for attaching a pour spout device to a container, particularly using ultrasonic sealing, are complex and require separate equipment for welding the spout and tamper-evidence arrangement, complicating the production process.
Innovation Solution
A pour spout device with an externally threaded spout, internally threaded cap, and tamper-evidence arrangement is welded simultaneously to the container wall using a single ultrasonic sealer, simplifying the process and apparatus by integrating the welding of the device and tamper-evidence arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate equipment is used for welding the spout and tamper-evidence arrangement, then each component can be welded with dedicated equipment, but the production process becomes complex and requires multiple pieces of equipment
Solution Approach 1:
The patent combines the welding of the spout flange and the tamper-evidence arrangement into a single simultaneous operation using one ultrasonic sealer. The L-section means is designed with a lower limb that can be welded to the flange while the upper limb provides tamper-evidence functionality, allowing both operations to be performed by one piece of equipment in one step.
Solution Approach 2:
The ultrasonic sealer is designed to perform multiple functions: welding the spout flange to the container wall and welding the L-section means to the flange. This multi-functional approach eliminates the need for separate welding equipment for different components, simplifying the overall production apparatus while maintaining welding quality.
2Reliability
If separate equipment is used for welding the spout and tamper-evidence arrangement, then each welding operation can be optimized, but the production time increases due to sequential operations
Solution Approach 1:
The patent merges two separate welding operations into one simultaneous operation. The L-section means is designed to be welded to the flange while the spout is simultaneously welded to the container wall, allowing both connections to be made in a single pass through the ultrasonic sealer, thereby reducing production time while maintaining welding quality.
Solution Approach 2:
The welding process continues without interruption by performing both the spout-to-wall and L-section-to-flange welds in a single continuous operation. This eliminates the need to stop, reposition, or reconfigure equipment between operations, maintaining continuous productive action throughout the welding process.
3Ease of manufacture
If the lower limb of the L-section is made weldable to the flange, then the tamper-evidence arrangement can be integrated with the spout, but the design complexity of the cap increases
Solution Approach 1:
The cap is segmented into functional components: the main cap body, the L-section means with upper and lower limbs, and the tamper-evidence bridge. This segmentation allows each component to be designed and manufactured separately with optimized geometries, then assembled together. The lower limb of the L-section is designed with specific geometries that facilitate welding to the flange while maintaining the overall cap structure integrity.
Solution Approach 2:
The L-section means is nested within the cap structure, with the upper limb extending to provide tamper-evidence functionality and the lower limb extending to weld to the flange. This nested arrangement allows the tamper-evidence feature to be integrated into the cap without requiring a completely separate structural element, reducing overall design complexity while maintaining functionality.
4Productivity
If simultaneous welding is used, then production efficiency increases, but the equipment requires precise coordination of multiple welding zones
Solution Approach 1:
The ultrasonic sealer is designed with localized welding zones that can be independently controlled and positioned. The lower limb of the L-section and the flange are positioned to receive simultaneous welding action, with the equipment capable of coordinating multiple welding zones through precise local quality control, ensuring consistent results without excessive complexity.
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 approach streamlines the production process by using a single piece of equipment for both attaching the pour spout device and welding the tamper-evidence arrangement, enhancing efficiency and reducing production complexity.
Implementation Method 1
weld an upper surface of a flange of a pour spout of a screw-capped, thermoplastics, pour spout fitment, commonly by ultrasonic sealing
Data Source
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AI summary
A pour spout device (2) for applying to a wall (4) of a container comprises an externally threaded pour spout (6) having a flange (20) projecting outwardly from a lower end zone thereof, and an internally threaded cap (8) for closing the pour spout (6), the cap (8) including a substantially L-section arrangement (8B,8C) projecting downwardly from a body (8A) of the cap (8), the lower limb (8B) of the substantially L-section arrangement (8B,8C) being weldable to an upper surface of the flange (20), and the upper limb (8C) of the substantially L- section arrangement (8B,8C) including frangible, tamper-evident bridges (8C). Welding of the lower limb (8B) to the flange (20) and/or to the wall (4) is substantially simultaneous with welding of the flange (20) to the wall (4).