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Cap & Liner Assembly Processes

Cap & Liner Assembly Processes

June 07th, 2018

Cap & Liner Assembly Processes

Author:  Avery Hallett - Applications Engineer II

Common methods of assembling liners and caps together:
• Press Fit
• Glue Fit
• Ultrasonic
 

Press Fit- A liner is manually or mechanically pressed into a cap using friction to help hold the liner in place. Liners are typically slightly oversized, compared to glue fit or ultrasonic, to allow for an interference fit. Some caps are specifically designed for press fitting. These caps will have a retaining ring or bead which has a smaller inner diameter than the base of the cap where the liner sits. In this instance, the liner is pushed past the retaining ring so that it is held in place along the area surrounding the outer diameter of the liner.

Glue Fit- Glue is dispensed onto the inside of a cap before a liner is pressed into place. The glue helps keep the liner from falling out. Various glues are available depending on the material(s) being used. The glue can be dispensed in different ways to better fit the product, such as center dispensing, edge dispensing, or custom point dispensing. In any scenario, the liner needs to be pressed into the cap to distribute the glue along the designated area of the liner surface. The glue then needs time to dry for best adhesion. The timing for the glue to dry will vary based on amount used, type of glue, and the cap and liner materials.

Ultrasonic- A liner is placed into a cap and welded together using an ultrasonic frequency to keep the liner from falling out. An anvil will press and hold the liner in the cap while a horn tuned to a specific frequency makes contact with the top of the cap. The frequency is then sent through the horn and into the cap. This frequency will shake the cap rapidly. While this is happening, the anvil is holding the liner in place, creating friction between the liner and the cap. This friction will cause a melting between the cap and liner, fusing them together. After a very short amount of time, the materials will have cooled into a solid bond. For this to occur, the liner requires a backing material to contact the cap. This backing material needs to be the same material as the cap material for a bond to occur. Unlike materials have different melt points which make the bond either unreliable or non-existent. This holds true even if attempting to bond a homopolymer to a copolymer with the same base resin. Custom horns and anvils can be made to fit various cap sizes and shapes. The custom anvils and horns can also focus the energy in select areas of the cap which can be beneficial if you have an open top cap or a large surface area.

  Bond Type
Pros vs Cons Press Fit Glue Fit Ultrasonic
Pros Fast pace manufacturing operation Helps keep liner from falling out Best bond for keeping liners from falling out
Does not require any backing material on the liner Different glues, amounts, and dispensing locations can be used Fast pace manufacturing operation
No added particulate Does not require any backing material on the liner Custom horns and anvils can be created
Cons Highest rate of liner fall-out Slow pace (comparatively) required for dispensing glue Requires a backing material in the same material as the cap
Set time required for glue Can leave marks on the cap which are especially visible on clear caps
Added chemicals of the glue

 

About Saint-Gobain

Saint-Gobain designs, manufactures and distributes materials and solutions which are key ingredients in the wellbeing of each of us and the future of all. They can be found everywhere in our living places and our daily life: in buildings, transportation, infrastructure and in so many industrial applications.

 

Saint-Gobain Performance Plastics' group of businesses gather solutions to save energy, provide protection, improve comfort and sustain the environment for a variety of markets.

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Saint-Gobain’s medical products are distributed exclusively to medical device manufacturers for use in the manufacture, assembly or distribution of their medical devices. Saint-Gobain cannot authorize the sale of its medical products directly to device user facilities (e.g. hospitals, surgery centers, nursing home, clinics, etc.), nor directly to end users (e.g. patients, patients’ caregiver, prescribing physician, nurse, pharmacist, etc.), including distributors serving device user facilities and end users directly. In accordance with every jurisdiction globally, Saint-Gobain’s customers are responsible for determining that any medical device they manufacture and market that incorporates a Saint-Gobain’s medical product, is compliant with each country-specific medical device regulations and has received proper country-specific clearance, certification or registration authorizing the sale of this medical device.


Saint-Gobain’s medical products offer covers:
- Medical Components [21 CFR 820.3(c)], intended for processing or use in the manufacture or assembly of medical devices before the finished medical device is packaged/labeled; Medical Components are intended to be included as part of the finished, packaged, and labeled device [21CFR820.3(c)].
- Finished Devices [21CFR820.3(l)] made on behalf of medical device manufacturers [21 CFR 807.20(a)(2)] under contract-manufacturing agreement. In accordance with the United States’ jurisdiction, Saint-Gobain complies with the FDA’s requirements for contract manufacturers of finished devices.

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