Thermoformed Gel Toilet Basket Joining Method
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Solution Overview
Problem
Current methods for producing toilet baskets filled with gel-like toilet active substances face challenges in material sustainability, resource efficiency, and controlled filling due to limitations in using recycled materials and the difficulty in containing the free-flowing gel-like substance without overflow or escape during filling.
Innovation Solution
The method involves joining the first and second container halves before filling, using thermoforming for both halves from plastic film, and creating a sealed connection to prevent escape, allowing for a larger volume of gel-like substance to be filled by utilizing the entire container capacity, with an opening in the second half for filling and a removable cover for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the container halves are joined before filling with gel-like toilet cleaner, then the container volume utilization is improved and larger quantity can be filled, but the risk of leakage during joining increases
Solution Approach 1:
The container halves are joined together before filling with the gel-like toilet cleaner. This preliminary joining action ensures that the container is properly sealed and structurally sound before the filling process, allowing for optimal volume utilization while preventing leakage during and after filling.
Solution Approach 2:
A hinge connection serves as an intermediary mechanism between the first and second container halves. The hinge allows for controlled joining and sealing of the container halves, providing a reliable connection that prevents leakage while enabling the container to be properly assembled before filling.
2Reliability
If the first container half is designed without openings to prevent gel escape, then containment reliability is improved, but the filling process becomes more difficult
Solution Approach 1:
The container is segmented into two halves with different functions: the first container half has no openings for containment, while the second container half includes a filling opening. This segmentation allows the container to maintain reliability during storage while enabling easy filling through the opening in the second half.
Solution Approach 2:
The filling opening is extracted and placed specifically in the second container half rather than being distributed throughout the entire container structure. This allows the first container half to maintain its sealed, leakage-proof design while the second half provides the necessary access for filling operations.
3Adaptability or versatility
If injection molding is used to manufacture toilet seats with recycled PP, then sustainability is improved, but optical transparency and aesthetics deteriorate
Solution Approach 1:
The patent adopts a disposable container concept where the container halves are made from thermoformed plastic film that can be easily manufactured and discarded after use. This approach prioritizes sustainability and cost-effectiveness over long-term durability and aesthetic appearance, aligning with the single-use nature of toilet cleaning products.
4Loss of substance
If thermoforming is used instead of injection molding, then material savings and sustainability are improved, but the suitability for certain materials like recycled PP is reduced
Solution Approach 1:
The manufacturing process parameters are changed from injection molding to thermoforming. This parameter change enables significant material savings by using thin plastic film that is thermoformed into container halves, reducing material consumption while maintaining functional requirements for the disposable container application.
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 approach enhances material utilization, sustainability, and prevents uncontrolled escape or overflow, enabling a toilet basket to hold a larger volume of gel-like substance efficiently while maintaining a secure and protected environment for the active ingredient.
Implementation Method 1
a gel-like toilet chemical (40), which has a gel phase and can be filled in a flowable or liquid state
Data Source
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AI summary
The invention relates to a method for manufacturing a toilet basket (1) with at least one container (10) in which a gel-like toilet active ingredient (40) is located, wherein the container (10) has a first container half (11) and a second container half (12), comprising the following method steps: a) manufacturing the first container half (11) and the second container half (12) of the container (10); b) filling the first container half (11) with the gel-like toilet active ingredient (40) in a flowable state; and c) joining the first container half (11) and the second container half (12) to form the container (10). The invention is characterized in that the joining of the first container half (11) and the second container half (12) takes place before filling with the gel-like toilet active ingredient (40) and the toilet active ingredient (40) is filled through an opening (16) in the second container half (12).