Disposable Aluminum Lid Rolled Corners for Safe Nesting
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Solution Overview
Problem
Existing disposable aluminum lids have sharp corner edges that can cause accidents and cannot nest properly, leading to inefficient shipping and storage due to their 90-degree angle design.
Innovation Solution
The improved disposable aluminum lid features a raised ridge with a downwardly extending skirt and a rolled lip that includes crimped and rolled corners, along with a 3-10 degree taper between the ridge and skirt, allowing for secure handling and efficient nesting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the dies are formed with only edge rolled lips and ninety degree angle walls, then the manufacturing process is simple, but the corners have sharp edges that can cut consumers and the lids cannot stack or nest properly
Solution Approach 1:
The patent applies local quality by differentiating the treatment of different parts of the lid. The corners receive special attention with rolled lips and crimped edges to eliminate sharp points, while the flat top surface maintains its original simple stamped appearance. This localized modification addresses the harmful sharp corners without complicating the overall manufacturing process.
Solution Approach 2:
The patent introduces curvature through rolled lips at the corners and along the edges. Instead of sharp 90-degree corners, the lips are rolled into curved, rounded forms that eliminate cutting hazards. The crimped corners further enhance this curvature effect, creating safe, rounded transitions that prevent consumer injuries while maintaining manufacturing efficiency.
2Ease of manufacture
If the edge walls extend at a ninety degree angle from the top edge, then the manufacturing process is simple, but the lids cannot stack and nest properly causing wasted shipping space
Solution Approach 1:
The patent modifies the vertical edge walls by adding curvature through rolled lips at the corners and along the edges. This curvature allows adjacent lids to nest more efficiently during stacking, as the rounded profiles interlock better than sharp 90-degree angles. The curved geometry reduces gaps and wasted space in shipping containers while maintaining the simplicity of the stamping process.
Solution Approach 2:
The patent explicitly addresses nesting capability by designing the lid geometry with rolled and crimped edges that facilitate stacking. The curved profiles allow lids to nest closely together in a nested doll configuration, maximizing space utilization in shipping cartons. This nesting design maintains manufacturing simplicity while dramatically improving storage and shipping efficiency.
3Ease of manufacture
If the corners are left unrolled with sharp edges, then the manufacturing process remains simple, but consumers frequently cut themselves on the corner edges
Solution Approach 1:
The patent applies local quality by specifically targeting the corner regions for modified treatment. The corners receive rolled lips and crimped edge treatments to eliminate sharp points, while the rest of the lid maintains its simple stamped geometry. This localized intervention addresses the harmful sharp corners without adding complexity to the overall manufacturing process.
Solution Approach 2:
The patent introduces curvature at the corners through rolled lips that transform sharp 90-degree angles into rounded, safe edges. The crimped corner treatment further enhances this curvature, creating doubly-rounded corners that are highly effective at preventing consumer injuries. This curvature application maintains manufacturing simplicity while eliminating the harmful sharp edges.
Data Source
AI summary
In accordance with one embodiment of the invention, there is provided an improved disposable aluminum lids configured for use with a pan. The lid has a continuously rolled lip around a skirt that when placed on the pan is bent to secure the two together. The rolled lip around the entire periphery of the skirt includes both the sides and the corners of the improved disposable aluminum lid. This significantly reduces the possibility of cuts and injuries to the user with securing the lid to the pan or removing it therefrom.