Vented Protective Cap With Segmented Filter Layers
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Solution Overview
Problem
The production of ventilated protective caps for liquid dispensers is complex and costly due to the need for multi-layer flexible surface materials, making it economically unfeasible for small series production, while existing solutions do not effectively balance air exchange with germ prevention.
Innovation Solution
A ventilated protective cap design featuring a flexible surface structure with multiple layers that are not firmly connected in the central region, allowing for cost-effective adaptation to specific requirements, including a sterile filter, absorbent, and antibacterial layers, which are held in place by a support structure or thermally attached, enabling air exchange while preventing germ entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multilayer flexible sheet material with sterile filter is used, then germ prevention and air exchange are improved, but production complexity and cost increase significantly
Solution Approach 1:
The surface structure is divided into multiple independent layers (first layer, second layer, third layer) that are not firmly connected to each other. Each layer can be produced separately and then assembled, reducing production complexity while maintaining the germ prevention and air exchange functions. The layers are held together only at the edge region, allowing independent production of each layer.
Solution Approach 2:
A support structure is introduced as an intermediary element to hold the multiple layers in place. The support structure with support surface provides a framework that maintains the spatial arrangement of the layers without requiring them to be firmly connected to each other, simplifying production while ensuring structural integrity.
2Stability of the object's composition
If multiple layers are firmly connected to create a composite material, then structural stability is improved, but production cost and complexity increase
Solution Approach 1:
The layers are segmented into separate components that are not firmly connected across their entire surface. Only the edge regions are connected to the support structure, allowing each layer to be manufactured independently and reducing production costs while maintaining sufficient structural stability for the application.
Solution Approach 2:
The connection between layers is applied locally only at the edge regions rather than across the entire surface. This localized connection provides sufficient structural stability at the boundaries while allowing the central regions to remain independent, reducing manufacturing complexity and cost.
3Reliability
If a sterile filter with small pore size is used, then germ prevention is improved, but air exchange efficiency decreases
Solution Approach 1:
Multiple layers with different properties are combined in a composite structure. The first layer can be a sterile filter with small pores for germ prevention, while the second and third layers can have different pore structures or material properties that facilitate air exchange. The composite structure achieves both germ prevention and efficient air exchange by leveraging the complementary properties of each layer.
Solution Approach 2:
The surface structure utilizes porous materials with varying pore sizes and distributions across different layers. The first layer employs fine-pore material for filtration, while subsequent layers use coarser porous materials that maintain structural integrity while allowing efficient air passage, thus balancing germ prevention with air exchange efficiency.
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 design allows for effective air exchange while preventing germ entry, is cost-effective for small series production, and can be customized with various layers for specific functions, enhancing the safety and efficiency of liquid dispensers.
Implementation Method 1
a layer designed as a sterile filter is included. This preferably has a maximum separation limit of 1 μm, particularly preferably a maximum separation limit of 0.5 μm. Even better sterility can be achieved with a maximum separation limit of 0.2 μm. Such a sterile filter prevents germs from entering through the ventilation opening.
Implementation Method 2
One layer of the surface structure can be designed as an absorbent layer intended to absorb a residual drop from a dispenser's discharge opening.
Implementation Method 3
in an edge region, they can be connected to one another during production, in particular by joint overmolding with plastic or thermally joining them.
Data Source
Figure 1~2
Figure 3A~3C
Figure 4A~4D
AI summary
The invention relates to a ventilated protective cap (10) for a liquid dispenser (100) and a ventilation insert, in particular for such a protective cap. The protective cap (10) has a cap wall (12) that surrounds a cap interior (14). The cap wall (12) has a ventilation opening (16) spanned by a flexible surface structure (18). An edge region (18A) of the surface structure (18) is fixed circumferentially to an edge of the ventilation opening (16). The surface structure (18) consists of at least two layers (20, 22) that are in direct contact with one another, but are not rigidly connected to each other at least in a central region (18B) of the surface structure (18).