Refill Container Fitment Design for Reusable Shell Packaging
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Solution Overview
Problem
Consumer products packaged in plastic containers often end up in landfills, contributing to environmental waste, and while refills are a sustainable option, they require effort and awareness from consumers, who may not find them convenient or attractive.
Innovation Solution
A refill container system featuring a thin-walled or flexible product chamber within a rigid outer shell container, with a fitment that supports the refill for easy display and use, minimizing material usage and environmental impact, and incorporating a snap-fit closure with a visible button for easy operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid plastic containers are used for consumer products, then product protection and durability are improved, but environmental waste and landfill contribution increase
Solution Approach 1:
The packaging system is divided into two segments: a reusable rigid outer shell container and a disposable flexible refill pouch. The rigid shell provides structural strength and protection, while the flexible pouch contains the product. This segmentation allows the rigid portion to be reused multiple times, reducing environmental waste, while only the flexible pouch is discarded after use.
Solution Approach 2:
The flexible refill pouch is nested inside the rigid outer shell container. The pouch is inserted through an opening in the shell, and the shell's internal ledge supports the pouch's fitment. This nesting arrangement protects the flexible pouch during shipping and storage while enabling easy removal and replacement of the refill.
2Loss of substance
If refill containers are provided with minimal packaging, then environmental impact and material usage are reduced, but consumer convenience and ease of use deteriorate
Solution Approach 1:
The rigid outer shell container acts as an intermediary between the flexible refill pouch and the consumer. The shell provides a sturdy, easy-to-handle structure with a snap-fit closure mechanism, while the flexible pouch remains minimal and lightweight. The shell's closure system and support ledge mediate the interaction, making the refill easy to insert, remove, and use without requiring the consumer to handle the fragile flexible pouch directly.
Solution Approach 2:
The rigid outer shell container serves multiple functions: it protects the flexible pouch during shipping, provides a reusable storage container after the pouch is emptied, offers a sturdy grip for consumers, and includes a closure mechanism to prevent leakage. This multi-functionality enhances consumer convenience without adding significant material usage, as the same shell can be reused with multiple refills.
3Loss of substance
If thin-walled flexible refill containers are used, then material usage and environmental impact are minimized, but structural support and stability worsen
Solution Approach 1:
The rigid outer shell container provides counterweight and structural support to the thin-walled flexible refill pouch. The shell's rigid structure compensates for the pouch's lack of structural integrity, allowing the pouch to be made from minimal materials while still providing adequate protection and support during handling, shipping, and storage.
Solution Approach 2:
The rigid outer shell container is prepared in advance with an opening and internal ledge structure designed to receive and support the flexible refill pouch. The shell is manufactured with predetermined structural features that provide support before the pouch is inserted, ensuring that the thin-walled pouch receives immediate structural assistance upon insertion without requiring self-supporting walls.
4Ease of operation
If refills are designed for easy removal and display, then consumer attraction and usability are improved, but device complexity increases
Solution Approach 1:
The flexible refill pouch is extracted from the rigid outer shell container through a predetermined opening. The shell's internal ledge and the pouch's fitment are designed to work together to guide the removal process. The opening is positioned and sized to allow easy extraction without requiring complex mechanisms, and the ledge provides a stopping point that prevents the pouch from being pulled out too far, simplifying the removal action.
Solution Approach 2:
The rigid outer shell container is pre-configured with an opening and internal ledge structure that facilitates easy removal of the refill pouch. The opening is positioned and sized in advance to match the pouch's dimensions, and the ledge is pre-formed to provide support during both insertion and removal. This preliminary configuration eliminates the need for complex mechanisms during the refill operation.
Data Source
AI summary
A discrete product refill container and a rigid outer shell container. The refill container includes a product chamber and a fitment secured thereto. The fitment includes a ledge which is suitable for resting on a ledge of the rigid outer shell container while permitting the product chamber to pass into the shell interiorly to the ledge. It may also include a rim for grasping by transfer equipment. The fitment includes a destructive cover, i.e., one which cannot readily be re-closed, so that the consumer can easily make the product within the refill available for pumping, as desired. The rigid outer shell container can be snap fit closed. The refill bottle may be a pouch or a thin walled bottle, with a fitment. The fitment may serve to support the bottle in an inverted position for display or storage. The refill bottle may also include an integral ledge for support in the rigid outer shell container, instead of a discrete fitment. A modular fitment may be used which accommodates different types of closures, if desired.