Sealed Container Lid Insulating Flange Joining Without Caulking Variations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing sealed container lids with insulating members between the lid body and the terminal face challenges such as variations in caulking, insufficient joining strength, and difficulties in small-lot production and maintaining insulation distance.
Innovation Solution
A method involving a conductive lid body with a terminal mounting hole, a conductive terminal with a shaft and flange, and an insulating thermoplastic resin member with a cylindrical and flange portion. The insulating flange is heated and pressed between the lid body and terminal flange using pressure portions, ensuring proper joining and sealing without the need for a mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insulating member is provided by caulking and fixing, then the terminal is fixed to the lid body, but variations in caulking amount occur and sealing performance is insufficient
Solution Approach 1:
The insulating member is heated to melt the thermoplastic resin, changing its physical state from solid to liquid and back to solid upon cooling. This phase change enables the resin to flow and fill gaps, creating consistent sealing without relying on precise caulking amounts. The heating temperature and duration are controlled parameters that ensure repeatable sealing quality.
Solution Approach 2:
The thermoplastic resin in the insulating member undergoes melting and solidification phase transitions. When heated, the resin melts and flows to conform to the interface between the terminal and lid body, then solidifies to create a strong, consistent seal. This phase transition eliminates variations associated with mechanical caulking methods.
2Manufacturing precision
If the insulating member is provided by injection molding, then the insulating member is formed with good shape, but joining strength may be insufficient and mold is required making small-lot production difficult
Solution Approach 1:
The insulating member is pre-formed with a basic shape and then heated in place to melt the resin. This preliminary formation followed by in-situ heating allows the insulating member to achieve both good shape and adaptability, eliminating the need for complex injection molds while maintaining manufacturing precision. The heating step enables the pre-formed member to conform to the interface surfaces.
Solution Approach 2:
The injection molding mechanical system (mold, injection apparatus) is replaced with a thermal field system. Instead of mechanically injecting and forming the insulating member, a pre-formed member is heated to melt the resin, which then flows and solidifies to create the sealed structure. This substitution eliminates mold requirements while maintaining manufacturing precision.
3Strength
If the insulating member is heated and melted after caulking and fixing, then the insulating member is joined to the lid body and terminal, but the insulating member may be deformed and insulation distance may not be secured
Solution Approach 1:
The insulating member is positioned and fixed in the correct position before heating. This preliminary positioning ensures that when the resin melts and flows, the insulating member maintains its proper location and the insulation distance is preserved. The heating step then enhances joining strength without compromising the pre-established insulation distance.
Solution Approach 2:
The heating temperature and duration are carefully controlled to melt the resin sufficiently for joining while avoiding excessive deformation. By optimizing these parameters, the insulating member achieves strong bonding to both the terminal and lid body while maintaining the required insulation distance and geometric integrity.
4Strength
If the insulating member is heated in the pressured state, then the insulating member is joined to the lid body and terminal, but melted resin is pushed out of the interface and sealing performance is reduced
Solution Approach 1:
The insulating member is positioned and lightly fixed before heating, allowing the resin to flow and fill interfaces without excessive pressure. This preliminary positioning without strong pressure prevents resin expulsion while ensuring proper placement. The heating step then creates strong bonding through controlled resin flow and solidification.
Solution Approach 2:
The heating temperature is controlled to melt the resin to an appropriate viscosity that allows it to flow into and fill the interfaces between the insulating member, terminal, and lid body. By optimizing the heating parameters, the resin flows sufficiently to create strong joints without being pushed out of the interfaces, thereby maintaining both joining strength and sealing performance.
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 method efficiently manufactures sealed container lids with enhanced sealing properties and insulation, while allowing for small-lot production without the need for a mold, and ensures high joining strength and insulation distance.
Implementation Method 1
the lid body and the terminal flange are heated by induction heating
Data Source
AI summary
A method for manufacturing a sealed container lid includes arranging an insulating flange 42 so as to overlap with a terminal flange 32, heating the insulating flange 42 overlapping with the terminal flange 32, pressing the insulating flange 42 on the terminal flange 32 in a state where a pair of pressure portions 55, 56 sandwich the terminal flange 32 and the heated insulating flange 42, and joining the insulating flange 42 to the terminal flange 32, arranging the insulating flange 42 so as to overlap with a lid body 15, heating the insulating flange 42 overlapping with the lid body 15, and a pressing the insulating flange 42 on the lid body 15 in a state where the pair of pressure portions 55, 56 sandwich the lid body 15 and the heated insulating flange 42, and joining the insulating flange 42 to the lid body 15.