Seamless Sheet-Metal Package With Tear-Off Foil Leak-Proof Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packages with tear-off foil covers face issues such as contamination, faulty sealing, leakages, increased material and production costs, and limited production speed due to weld seams and additional components.
Innovation Solution
A seamless package frame made by deep drawing, with a sealing flange extending radially outward, allowing for a tear-off foil cover and a sheet metal cover to form a leak-proof, stackable, and efficiently producible package without weld seams, using identical sheet materials for both components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two-piece packages with tear-off foil covers are used, then the structure is simple, but contamination occurs and sealing fails leading to leakage
Solution Approach 1:
The package is divided into three separate components: a container body, a separate sealing flange component, and a tear-off foil cover. The sealing flange is formed as a distinct element that is crimped onto the container body, separating the sealing function from the container structure itself. This segmentation allows the sealing surface to remain clean and uncontaminated during filling operations while maintaining structural integrity.
2Reliability
If three-piece packages with weld seams are used, then sealing capability is improved, but weld seams cause leakage problems
Solution Approach 1:
The sealing flange is extracted as a separate component from the container body, eliminating the need for weld seams to join these elements. The sealing flange is instead mechanically crimped onto the container body, creating a leak-proof connection without thermal processing. This extraction removes the harmful weld seams that cause blackening and leakage while maintaining effective sealing capability.
3Reliability
If four-piece packages with additional sheet metal rings are used, then sealing is improved, but material and production costs increase
Solution Approach 1:
The sealing flange component combines multiple functions into a single element: it provides the sealing surface for the tear-off foil cover, creates the mechanical connection between the container body and bottom, and forms the structural framework for the package. This merging eliminates the need for separate sheet metal rings while maintaining improved sealing performance, thereby reducing material and production costs.
4Productivity
If two-piece packages are used, then production speed is limited, but high-speed filling is needed
Solution Approach 1:
The sealing flange is pre-formed and attached to the container body before the filling operation. The tear-off foil cover is pre-sealed to the sealing flange in a controlled environment. These preliminary actions ensure that the sealing surfaces are clean and properly positioned before high-speed filling begins, enabling both high productivity and reliable sealing quality during rapid production.
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 solution enables high-speed filling, reduces material waste, minimizes leakage risks, and ensures efficient production with cost-effective manufacturing processes, while maintaining the integrity of the contents.
Implementation Method 1
The sealing flange is surrounded by an extraction opening which is closed by a tear-off foil cover sealed or glued onto the sealing flange
Implementation Method 2
a seamless frame made by deep drawing, which forms a package wall enclosing the interior space of the package
Implementation Method 3
The second end of the frame is connected by flanging to a sheet metal cover which forms the bottom of the package
Data Source
AI summary
A package made of sheet material with a tear-off foil cover includes a seamless frame (1) produced by deep drawing, which forms a package wall (6) enclosing the interior space of the package. At a first end (T), the frame (1) forms an extraction opening surrounded by a sealing flange (2), which is closed by a tear-off foil cover (3) sealed onto the sealing flange (2). At its other, second end (B), the frame (1) is connected by flanging to a sheet metal cover (4) which forms the package bottom (7). The package can be produced inexpensively with low energy and material consumption from both steel sheet material and aluminum sheet material, has no weld seams, can be tested for leaks before filling, and enables high filling speeds.