Segmented PET Jar with Ultrasonic Welding for Recyclability
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Solution Overview
Problem
The personal care market seeks recyclable, refillable, and reusable packaging solutions that maintain a premium appearance and feel while reducing plastic usage and CO2 emissions, with existing jars not adequately addressing sustainability trends.
Innovation Solution
A jar composed of two separately formed PET components with a maximum wall thickness of less than 5mm, assembled via ultrasonic welding, featuring a removable polypropylene inner cup for recyclability and reusability, ensuring transparency and compatibility with the circular economy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the wall thickness of the jar is increased to provide a premium appearance and feel, then the aesthetic quality and perceived value improve, but the recyclability and environmental sustainability deteriorate due to increased plastic usage
Solution Approach 1:
The jar is divided into two separate components - an outer jar and an inner cup - each with optimized wall thickness. The outer jar provides the premium appearance with adequate thickness, while the inner cup has minimal thickness for functionality, together achieving both aesthetic quality and reduced plastic usage.
Solution Approach 2:
The inner cup is nested within the outer jar, creating a dual-layer structure. This nesting allows the outer jar to maintain premium appearance and feel while the combined structure uses less total plastic than a single thick-walled jar, and enables separate recycling of components.
2Loss of substance
If the wall thickness is reduced to improve recyclability and reduce plastic usage, then sustainability improves, but the premium appearance and feel deteriorate
Solution Approach 1:
The jar structure is segmented into outer jar and inner cup, allowing the outer jar to have sufficient wall thickness for premium appearance while the inner cup uses minimal material, achieving both aesthetic quality and reduced overall plastic usage.
Solution Approach 2:
The jar uses composite construction with two different PET components (outer jar and inner cup) that together provide the premium feel of thick walls while using less total plastic, optimizing both appearance and sustainability.
3Strength
If the jar is made from a single thick component to ensure structural strength, then the mechanical strength improves, but the recyclability and transparency deteriorate
Solution Approach 1:
The jar is segmented into two separate PET components with thin walls, each maintaining optimal thickness for transparency and avoiding crystallization. The assembly of these components provides the necessary structural strength while preserving clarity and recyclability.
Solution Approach 2:
The wall thickness parameter is optimized to be less than 5mm for both outer jar and inner cup to prevent crystallization and maintain transparency, while the dual-component structure compensates for the reduced individual wall thickness to provide adequate structural strength.
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 a 100% recyclable, refillable, and reusable jar that maintains a premium appearance and feel, optimizing wall thickness to prevent crystallization and reduce plastic usage, aligning with sustainability trends in the personal care market.
Implementation Method 1
The two components have less than 5 mm of thickness to avoid the crystallization in order to get maximum transparency... In some embodiments the components are welded together, for example ultrasonically welded together... The assembly of the components may be by ultrasonic welding machine
Data Source
Figure 1~4
Figure 5A~5C
Figure 6A~6C
AI summary
A jar (15) is provided and comprises two or more components (20, 25) which are formed separately and assembled together. Each of the components is formed from PET and each of the components has a maximum wall thickness of less than 5mm.