Rectangular Container Closure with Folded Pour Spout
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Solution Overview
Problem
Existing container designs for pourable products face issues with consumer usability, material efficiency, and leakage due to inadequate sealing and tearing mechanisms, particularly with Polyethylene (PE) coated paper board containers that fail to maintain air-tightness during distribution and consumer use.
Innovation Solution
A container design featuring two superimposed polymer coated paperboard panels with a heat sealed area between scoring lines and a controlled tearing path, utilizing a film element with a ruptured pattern and interlocking edges for easy opening and resealing, which includes a pour spout that can be folded back for controlled pouring and resealed air-tight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Polyethylene (PE) film element is heat sealed inside the container closure, then the container provides a sealed closure, but the film element fractures during distribution due to tension, resulting in leaking containers
Solution Approach 1:
The closure is divided into multiple functional areas: a triangular closure opening area, a triangular pour spout area extending beyond it, and a rectangular sealing area. The PE film is selectively heat sealed in specific zones (inside the closure opening and outside the pour spout area) rather than across the entire closure, reducing stress concentration points while maintaining sealing reliability.
Solution Approach 2:
The PE film has different properties in different regions: it is heat sealed and taut in the closure opening area for security, while it is folded back 180° and creates a controlled tearing path in the pour spout area for easy opening. This local differentiation allows the film to provide both strong sealing and controlled failure modes.
2Stability of the object's composition
If a permanent film element is heat sealed to container panel walls, then the container maintains structural integrity, but the film element comes loose under tension from container cross section, resulting in leaking containers
Solution Approach 1:
The film sealing is segmented into distinct zones: internal heat sealing within the closure opening, external heat sealing outside the pour spout area, and a middle folded-back section. This segmentation allows each zone to perform its specific function without compromising the others, maintaining both structural integrity and film retention.
Solution Approach 2:
The film is folded back 180° in the pour spout area, transitioning from a flat 2D configuration to a 3D folded structure. This dimensional change creates a controlled tearing path and allows the film to accommodate the container's cross-sectional geometry without under-tension, preventing the film from coming loose during distribution.
3Ease of operation
If the pour spout area is made larger than the closure opening, then controlled pouring is enabled, but the closure cannot be resealed air-tight after opening
Solution Approach 1:
The pour spout area is designed to be dynamically transformable: in the closed state, it is folded back 180° to maintain air-tight sealing; during use, it can be unfolded to provide controlled pouring; after use, it folds back again to reseal. This dynamic behavior allows the closure to switch between sealed and pouring states while maintaining air-tightness in the closed position.
4Ease of operation
If four injection molded parts are used for pour and cap re-close attachment, then consumer acceptance is improved, but material consumption and production complexity increase
Solution Approach 1:
Multiple functions previously requiring separate injection molded parts (pour spout, closure opening, sealing surfaces) are merged into a single integrated paperboard closure structure. The PE film serves multiple purposes: sealing the closure opening, forming the pour spout, and providing the tearing path. This integration reduces part count, material consumption, and production complexity while maintaining consumer-friendly functionality.
Solution Approach 2:
The closure transitions from a rigid plastic structure to a flexible paperboard structure with heat-sealed PE film. This parameter change in material properties allows the closure to be formed through folding and heat sealing processes rather than complex injection molding, reducing manufacturing complexity while achieving the same consumer acceptance through controlled tearing and resealing mechanisms.
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 design enhances consumer usability, reduces material consumption, and ensures efficient production and distribution by providing a reliable, air-tight and easy-to-use container that minimizes leakage and environmental impact.
Implementation Method 1
Third and fourth index stations are heat activated by a nozzle/manifold moving over the sealing area with a hot air stream
Implementation Method 2
guided under two stationary guides before reaching the final fold configuration under a compression plate in fifth index station, having different levels (a pattern) with at least on integrated spring loaded element, for finally sealing the closure air tight & liquid proof
Data Source
Figure 1~9
AI summary
A closure on a rectangular container with a square or rectangular cross section with the closure easily opened into a pour spout. The container closure can be resealed. The new container provides a consumer friendly container design, reduced materials consumption, high efficiency from production capacity and distribution view points.