Seamless Sheet Metal Packaging for Clean Tear-Off Lid Sealing
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Solution Overview
Problem
Existing packaging with tear-off lids, such as two-part, three-part, and four-part packages, suffer from issues like contamination during sealing, faulty seals, increased production costs, material waste, and limited production speed due to weld seams and separate components.
Innovation Solution
A seamless packaging design with a tear-off foil lid, featuring a deep-drawn frame connected to a sheet metal lid, eliminating weld seams and allowing filling from the bottom, enabling high-speed production and efficient material use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two-part packaging with tear-off film is used, then the structure is simple, but the sealing surfaces become contaminated during filling leading to faulty seals and limited production speed
Solution Approach 1:
The packaging is divided into three separate parts: a frame, a separate lid, and a tear-off foil. This segmentation allows the frame to be filled from the end opposite the foil lid, preventing contamination of the sealing surfaces while maintaining structural simplicity
Solution Approach 2:
A separate lid acts as an intermediary component between the frame and the tear-off foil. This lid provides a dedicated sealing surface that can be sealed with the foil without being contaminated during the filling process, thus ensuring reliable seals
2Reliability
If three-part packaging with rolled and welded sheet metal ring is used, then the container can be sealed at both ends, but the weld seam traverses the sealing flange radially causing sealing problems
Solution Approach 1:
The welding operation is extracted from the sealing flange area and relocated to the frame body. The frame is welded into a closed ring structure before the sealing flange is formed, ensuring that no weld seams traverse the sealing flange radially and compromising seal integrity
3Reliability
If four-part packaging with additional sheet metal ring is used, then the sealing flange can be separate, but the additional component increases material and production costs and creates waste
Solution Approach 1:
The sealing flange is merged with the frame as an integrated component formed by deep drawing. The frame is formed as a single piece with the sealing flange already incorporated, eliminating the need for separate sheet metal rings while maintaining the sealing function
4Strength
If separate metal lid for packaging base is provided, then the lid can be securely attached, but material and production costs and waste significantly increase
Solution Approach 1:
The lid and the frame are merged into a single component formed by deep drawing. The frame is formed as one piece with the lid already integrated, eliminating the need for separate metal lids and reducing material waste while maintaining secure attachment through the crimped connection
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 provides leak-resistant, cost-effective packaging with high filling speed, good stackability, and minimal material waste, ensuring high-quality seals and efficient manufacturing processes.
Implementation Method 1
a seamless frame produced by deep drawing, which forms a packaging wall enclosing the interior of the packaging
Implementation Method 2
The second end of the frame is connected by crimping to a sheet metal lid
Implementation Method 3
which is closed with a tear-off foil lid glued or sealed onto the sealing flange
Data Source
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AI summary
The invention relates to packaging made of sheet metal material with a tear-off foil lid. The packaging comprises a seamless frame (1) produced by deep drawing, which forms a packaging wall (6) enclosing the interior of the packaging. At a first end (T), the frame (1) forms a removal opening surrounded by a sealing flange (2), which is closed with a tear-off foil lid (3) sealed onto the sealing flange (2). At its other, second end (B), the frame (1) is connected by flanging to a sheet metal lid (4) that forms the packaging base (7). The packaging according to the invention can be produced inexpensively from both sheet steel and sheet aluminium with low energy and material costs, has no weld seams, can be tested for leaks before filling, and enables high filling speeds.