Sealed Single-Dose Break-Open Package With Segmented Incision
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Solution Overview
Problem
Existing sealed single-dose break-open packages face challenges in easy opening without accidental tearing, unhygienic product contact, and uncontrollable flow of liquid products, while their production methods result in weak seals and air inclusion, affecting shelf life and appearance.
Innovation Solution
A sealed single-dose break-open package design featuring a rectangular sheet of semirigid plastic with a crosswise central incision for controlled breakage, combined with a flexible plastic sheet, and a packing machine with a scoring and sealing process that forms strong, air-tight packages with adjustable outflow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a straight central incision is used for break-open, then the package is easy to open, but the product flows out extremely fast with no flow regulation
Solution Approach 1:
The incision is segmented into multiple portions (first, second, and optionally third portions) with different depths. The first portion has a greater depth than the second portion, creating staged breakage zones that control the flow rate. This segmentation allows the package to be easily opened while regulating product flow through the progressively deeper incision segments.
Solution Approach 2:
Different portions of the incision have different local qualities (depths). The first portion is deeper to allow initial breakage and product flow, while the second portion is shallower to control and regulate the flow rate. This local variation in incision depth creates zones with different flow characteristics, enabling both easy opening and flow control.
2Productivity
If a V-shaped incision is used to limit breakage to central part, then flow control is improved, but it fails to effectively solve the problem of controlling outflow easily and intuitively
Solution Approach 1:
The incision is divided into multiple segmented portions with clearly defined different depths. The first portion extends deeper than the second portion, creating distinct breakage zones. This segmentation provides intuitive control as users can naturally progress through the incision segments, with the deeper first portion allowing initial flow and the shallower second portion regulating subsequent flow.
3Ease of manufacture
If transverse sealing is performed once, then the process is simple, but the seals are weak and packages contain large amount of air
Solution Approach 1:
The transverse sealing process is segmented into a first transverse sealing operation and a second transverse sealing operation. The first sealing creates an initial seal, and the second sealing reinforces it to create a stronger, more reliable seal. This segmented approach improves seal strength and reduces air inclusion while maintaining manufacturing efficiency through automated sequential operations.
4Speed
If semirigid plastic sheet is broken instantaneously along the whole incision, then opening is fast, but the outlet is very large causing uncontrollable flow
Solution Approach 1:
The incision is segmented into portions of different depths, causing the semirigid plastic sheet to break in a sequential manner rather than instantaneously. The deeper first portion breaks first, creating an initial outlet, while the shallower second portion breaks subsequently, regulating the final outlet size. This segmented breakage maintains fast opening while controlling outflow through the staged rupture sequence.
Solution Approach 2:
The breakage process is made dynamic and progressive rather than static and simultaneous. The differential depths create a time sequence in the breakage propagation, where the incision progresses from the deeper first portion to the shallower second portion. This dynamic breakage sequence controls the evolution of the outlet size, enabling both speed and flow control.
Data Source
AI summary
A sealed single-dose break-open package (1) having: a first sheet (2) of semirigid plastic material; a second sheet (3) of flexible plastic material superimposed on and sealed to the first sheet (2) of semirigid plastic material to define a sealed pocket (4) containing a dose of a product (5); and an incision (6) formed in the first sheet (2) of semirigid plastic material to guide controlled breakage of the first sheet (2) along the incision (6) and form an outlet opening for the product (5) through the first sheet (2); the incision (6) varies in depth lengthwise to break the first sheet (2) gradually along the incision (6).