Reese's Popcorn Salt is packaged in a glass jar, with a rim around the mouth of the jar, over which a perforated soft plastic cap snaps. There is a normal plastic screw lid to keep salt in and moisture out. To use, unscrew the outer lid, exposing the perforated lid through which the desired amount of salt can be sprinkled on the popcorn.
The problem arises when the perforated cap is improperly trimmed. Typically, a high-volume plastic injection molded part will be produced in a multi-cavity mold with runners between the cavities to allow the plastic to flow into all cavities. When the parts are ejected, they will be connected by the runners and trimmed into single parts. If the blend of cuts is imprecise, there will be a small nib protruding where the mismatch occurs. In this case, if the nib does not extend beyond the minor diameter of the cap thread, everything works well.
However, if the perforated lid is slightly concaved outward when the lid is screwed down tightly, the sides of the perforated top flare out. The nibs can move to a position where they are able to engage the screw threads on the cap and move off the jar. This causes an unsuspecting user to empty the entire jar of salt onto their popcorn if they are not paying attention. If you do notice, a few seconds with an ice pick will extract the perforated top, which can then be snapped into place, and you can enjoy your popcorn as you like it -- until the next time anyway. Or you can take a sharp knife and try to remove the nibs, which the monkeys left for your enjoyment.
This entry was submitted by Ralph Wirtel and edited by Rob Spiegel.
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