Tabbed Sealing Member with Non-Foam Sub-Tab for Heat Management
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Solution Overview
Problem
Existing container sealing technologies face issues with foam layer damage during heat sealing, leading to uneven seals and exposure of underlying layers, and top-tabbed seals struggle with heat transfer and material efficiency in two-piece liner and seal assemblies.
Innovation Solution
Incorporating non-foamed polymer sub-tab layers between the tab and foam layers in a multi-layer laminate to enhance concentric stability and heat management, and forming the tab within the perimeter of the sealing member with a partial upper laminate structure to improve grasping and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a foam layer is included in the sealing member to provide insulation, then heat insulation performance is improved, but the foam layer can be damaged or deteriorate during the cap sealing process due to heat and pressure from the annular bead
Solution Approach 1:
The sealing member is divided into multiple functional layers: an outer layer containing the tab, a foam layer for insulation, and an inner heat seal layer. This segmentation allows each layer to perform its specific function while protecting the foam layer from direct contact with the annular bead during sealing, preventing foam damage while maintaining insulation performance.
Solution Approach 2:
The tab structure acts as an intermediary element between the consumer and the sealed container. By providing a dedicated gripping tab that extends beyond the container rim, consumers can easily grasp and remove the sealing member without needing to apply pressure to the foam layer or risk damaging it during the removal process.
2Ease of operation
If side tabs extend outwardly from the seal to provide a grasping surface, then ease of removal is improved, but the side tabs can be deformed or wrinkled when the closure is placed on the container due to contact with the closure threads
Solution Approach 1:
The tab structure is segmented into a gripping portion that extends beyond the container rim and a bonded portion that is heat-sealed to the container. This segmentation allows the gripping portion to provide a deformation-free grasping surface while the bonded portion maintains structural integrity during the sealing process.
Solution Approach 2:
The tab is designed to extend in a radial direction beyond the container rim, creating a three-dimensional structure that provides a grasping surface in a different spatial dimension. This eliminates the need for the tab to extend horizontally over the container side, preventing contact with closure threads and subsequent deformation.
3Area of moving object
If a full layer of material is used to form the tab, then grasping area is improved, but material usage and device complexity increase
Solution Approach 1:
The tab structure concentrates material and structural complexity only where needed for gripping functionality, rather than using a full layer across the entire sealing member. The tab provides adequate grasping area through localized reinforcement at the gripping portion, while the remainder of the sealing member maintains a simpler, more material-efficient structure.
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 robust, concentrically stable sealing member that minimizes foam damage and enhances heat transfer, allowing for easier removal and improved functionality in both one-piece and two-piece seal configurations.
Implementation Method 1
a metal layer for heating the seal layer
Implementation Method 2
a polymer foam layer above the metal layer
Implementation Method 3
a lower heat activated sealing layer to secure a periphery of the seal to a rim or other upper surface surrounding the container's opening
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A multi-layer laminate for forming a tabbed sealing member for sealing to a rim surrounding a container opening, the multi-layer laminate comprising: a lower laminate portion (14) including at least a heat seal layer (100) for bonding to a container rim, a metal layer (104) above the heat seal layer for heating the heat seal layer, a polymer foam layer (106) above the metal layer, and at least one non-foam film support layer (108) above the polymer foam layer; and an upper laminate portion (12) including one or more layers and partially bonded to the lower laminate portion and forming a gripping tab defined wholly within a perimeter of the sealing member.