Optimized impact resistance in sealed plastic cup lids through integrated finite element analysis and drop tests

This study explores the impact of varying rim widths on the structural integrity and impact resistance of plastic cup lids sealed with laminate film. Employing a quantitative approach, Finite Element Method (FEM) simulations and empirical drop tests were conducted to address a notable gap in the field of packaging engineering. The research findings reveal that decreasing the rim width from 5 mm to 2 mm significantly lowers the threshold for damage from a drop height of 1.55 meters to approximately 1.30 meters, underscoring a direct relationship between rim width and lid durability under transportation stresses. The study highlights that narrower rims lead to heightened stress concentrations at lower drop heights, thus increasing the likelihood of structural failure. Integrating water hammer theory helped elucidate the dynamic responses within the cup structure during impact, providing a detailed analysis of how stress distribution and failure modes are influenced by changes in rim width. Practical implications of this research are substantial, offering actionable insights for the packaging industry on designing more robust and resource-efficient packaging solutions. By reducing rim width, manufacturers can achieve cost savings and environmental benefits through decreased material usage while maintaining product integrity. Future research directions proposed include applying these insights to a broader range of packaging materials and enhancing the environmental scope of the models to increase their applicability and predictive accuracy in real-world scenarios