Two-Part Disposable Cup Lid with Rotating Closure Mechanism
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Solution Overview
Problem
Conventional disposable recloseable lids made from thermoplastic are limited by the one-step manufacturing process, resulting in less durable and less reliable closure mechanisms due to the inherent properties of thermoplastic, which oppose the formed shape, leading to inconsistent sealing and increased production costs.
Innovation Solution
A two-part thermoformed lid design where a pivoting arm is fabricated separately and assembled off-center, allowing for a rotating closure mechanism that does not oppose the natural structural properties of the thermoformed plastic, enhancing the reliability and precision of the closure while reducing material usage and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-step thermoplastic manufacturing process is used for disposable lids, then production cost is reduced and manufacturing efficiency is improved, but the closure mechanism becomes less reliable and less precise
Solution Approach 1:
The lid is divided into two separate parts: a thermoplastic lid body and a closure mechanism. The closure mechanism is manufactured separately using a more precise process and then attached to the lid body, allowing each component to be optimized independently for its specific function while maintaining overall manufacturing efficiency.
2Quantity of substance
If thermoplastic material is used for disposable lids, then manufacturing cost is reduced, but the material properties oppose the formed shape creating resistance that prevents reliable reclosing
Solution Approach 1:
Separates the lid body material (thermoplastic) from the closure mechanism, allowing the closure to be made from material better suited for precise positioning and reliable sealing, while the lid body remains cost-effective thermoplastic.
Solution Approach 2:
Changes the material parameters of the closure mechanism to have less elastic recovery and more dimensional stability compared to standard thermoplastic, enabling the closure features to maintain their formed shape and provide reliable sealing without opposing material resistance.
3Device complexity
If reclosing features are integrated into the main body of the lid in a single-part process, then manufacturing is simplified, but the features must bend or flex creating resistance that prevents them from remaining in place
Solution Approach 1:
Separates the closure mechanism from the lid body, allowing the closure to be manufactured as a distinct component with features that do not require bending or flexing, thereby maintaining reliable positioning throughout use.
Solution Approach 2:
Instead of forming closure features by bending thermoplastic material (which creates elastic recovery resistance), the closure mechanism is formed separately and attached to the lid body, inverting the traditional approach to eliminate the bending resistance problem.
4Reliability
If reusable lid manufacturing methods are used with two separate parts and injection molding, then closure precision and reliability are improved, but manufacturing cost increases significantly
Solution Approach 1:
Divides the lid system into two parts manufactured by different processes: the lid body using cost-effective thermoplastic forming and the closure mechanism using precise manufacturing methods, then combines them. This segmentation allows reuse of the precise closure mechanism across multiple lids, reducing overall cost compared to fully reusable lids.
Solution Approach 2:
Creates a hybrid approach where the closure mechanism is designed to be durable and reusable across multiple lid units, while the lid body remains disposable. This reduces the quantity of expensive material needed compared to fully reusable lids while maintaining closure precision.
Data Source
AI summary
A two-part disposable, stackable and recloseable lid for a container holding a beverage. The lid has a dome configuration for higher volume beverages. The lid has a drinking aperture and an a moveable arm with a plug to seal the drinking aperture. The lid has a recess for storing the plug end of the arm when the drinking aperture is being used.