Resealable Inner Package Flap and Layer Design
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Solution Overview
Problem
Current container seal constructions face challenges in maintaining air tightness and functionality due to complex multilayer materials, which can lead to increased energy requirements, material damage, and potential gaps in seals, affecting the quality and production efficiency of sealed packages.
Innovation Solution
A container design featuring a multilayer inner package with a first and second layer, where the second layer is only applied to the inner surface of the first layer, reducing material thickness and energy needed for sealing, and incorporating a flap mechanism for easy access and resealing, attached to the lid using adhesives for improved sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex multilayer materials are used for sealing, then sealing effectiveness is improved, but energy consumption increases and material damage occurs
Solution Approach 1:
The inner package material is segmented into two distinct layers: a first layer providing structural integrity and a second layer providing barrier properties. This segmentation allows each layer to be optimized for its specific function, reducing the overall complexity and energy required for sealing while maintaining effective sealing performance.
Solution Approach 2:
The second layer is applied selectively only to the inner surface of the first layer where barrier properties are needed, rather than using a thick multilayer material throughout. This local application of quality ensures sealing effectiveness at critical areas while reducing overall material thickness and energy consumption during sealing operations.
2Reliability
If complex multilayer materials are used for sealing, then sealing effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The material structure is divided into two functional layers with distinct roles, simplifying the overall design compared to complex multilayer constructions. The first layer provides structural support while the second layer provides barrier functionality, making the material easier to manufacture and process.
Solution Approach 2:
The barrier functionality is extracted as a separate second layer applied to the inner surface of the first layer. This extraction allows the structural first layer to be manufactured independently and simplifies the overall material construction, reducing manufacturing complexity while maintaining sealing effectiveness.
3Object-affected harmful factors
If thicker multilayer materials are used, then barrier properties are improved, but sealing energy requirements increase
Solution Approach 1:
The second layer with superior barrier properties is applied locally to the inner surface of the first layer where it is most needed for sealing effectiveness. This localized application provides strong barrier protection against air and moisture ingress while keeping the overall material thickness reduced, thereby lowering sealing energy requirements.
Solution Approach 2:
The inner package uses a composite structure combining a structural first layer with a barrier-oriented second layer. This composite material approach provides enhanced barrier properties against air and moisture without requiring excessive thickness, as each layer contributes its specific protective function efficiently.
4Object-affected harmful factors
If full multilayer coverage is used, then barrier properties are improved, but material usage increases
Solution Approach 1:
The second layer is applied selectively to the inner surface of the first layer rather than covering the entire surface. This local application provides necessary barrier protection at critical areas where sealing is needed while significantly reducing overall material consumption.
Solution Approach 2:
The second layer is applied as a thin film on the inner surface of the first layer, providing effective barrier properties with minimal material thickness. This thin film approach ensures protection against ingress and egress of contaminants while minimizing material usage and waste.
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 design enhances air tightness, reduces material usage and energy consumption, and ensures cost-effective production of sealed packages that can be easily opened and closed to preserve freshness, while maintaining structural integrity and sealing efficiency.
Implementation Method 1
The flap is attached to an inner surface of the lid
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A container includes an inner package disposed within a housing. The inner package includes a first region that extends along a longitudinal axis of the inner package and includes first and second layers of a material that forms the inner package, and a second region adjacent the first region that also extends along the longitudinal axis. The second region includes only the first layer and not the second layer. The first region also includes a first line of weakness disposed in the first layer that defines a flap, and a second line of weakness disposed in the second layer that defines an access opening disposed in the first region. The access opening is covered by the flap when the flap is in a closed position and at least partially uncovered when the flap is in an open position.