Threadless Container Top with Removable In-Mold Seal
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Solution Overview
Problem
Conventional food container manufacturing is inefficient and costly due to separate processes for forming the main housing, applying the seal, and manufacturing the threaded top, and users find it tedious to open and close these containers.
Innovation Solution
A method for producing a container top with a threadless frame, flip cap, and in-mold lidding film that hermetically seals the opening, using a compound hinge and ultrasonic welding for attachment, allowing the seal to be peeled away without removing the top, and integrating the seal and top in a single molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate processes are used for forming the main housing, applying the seal, and manufacturing the threaded top, then each component can be manufactured with high precision, but the manufacturing time, materials, and expense increase
Solution Approach 1:
The patent combines the top and seal into a single integrated component manufactured through one molding process. The mold includes a frame portion that forms the top and a seal portion that forms the seal, with the seal portion being removable from the frame portion. This integration eliminates separate manufacturing and assembly steps while maintaining the precision of individual components through controlled molding parameters and material selection.
2Reliability
If threading is included on the threaded top and main housing, then the top can be securely attached, but the manufacturing complexity and time increase
Solution Approach 1:
The patent extracts the threading feature from the design, creating a threadless top and main housing. Instead of using threads for attachment, the integrated top-seal assembly relies on the hermetic seal between the seal portion and the container opening to secure the attachment. This eliminates the complex threading mechanism while maintaining secure attachment through the seal's engagement with the container rim.
3Reliability
If the user must unthread the top, remove the seal, and replace the top to use the container, then secure attachment is achieved, but the ease of operation deteriorates
Solution Approach 1:
The patent segments the top and seal into distinct functional portions within an integrated structure. The seal portion is designed to be removable from the frame portion, allowing the user to access the container contents by peeling or pulling the seal away from the top. This segmentation enables easy opening operation while the frame portion remains attached to the container, maintaining attachment security without requiring complete removal and reattachment of the top.
4Productivity
If a single molding process is used to integrate the top and seal, then manufacturing time and expense are reduced, but the manufacturing precision may deteriorate
Solution Approach 1:
The patent applies local quality by using different material properties for different portions of the integrated top-seal assembly. The seal portion is formulated with specific elastomeric properties to ensure precise fitting and hermetic sealing, while the frame portion uses rigid plastic material for structural integrity. The molding process incorporates localized temperature control, pressure distribution, and material injection parameters to achieve precise dimensional control in the seal area, ensuring proper fit and seal performance despite the integrated manufacturing approach.
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 reduces manufacturing time, materials, and expense by eliminating the need for threading and simplifying the opening and closing process, making the container more efficient and user-friendly.
Implementation Method 1
the heated thermoplastic resin contacts a perimeter of the heat-activatable lower surface of the in-mold lidding film, and the perimeter of the heat-activatable lower surface of the in-mold lidding film is molded to the frame of the article
Implementation Method 2
using a compound hinge and ultrasonic welding for attachment
Data Source
AI summary
A molded article comprising a container top is disclosed. The molded article includes a threadless frame defining an opening, a flip cap located substantially coplanar with, and integrally formed with, the frame, a compound hinge between the frame and the flip cap, the hinge allowing the flip cap to rotate about the hinge to rest on top of the frame, an in-mold lidding film having a perimeter molded to the frame such that the in-mold lidding film covers the opening defined by the frame, wherein the in-mold lidding film is removable from the frame, and a pull tab, formed from the in-mold lidding film, that extends past the opening defined by the frame.