Carton and Self-Supporting Plastic Liner Packaging System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current packaging systems for shipping liquid and viscous products are inefficient due to the use of rigid plastic containers that are costly, difficult to recycle, and wasteful in terms of space and material, while flexible 'bag & box' systems struggle with residue removal and mixing of ingredients.
Innovation Solution
A sustainable packaging system comprising a carton and a self-supporting plastic liner with a radially-extending flange and dependent skirt, allowing for efficient stacking and use of recyclable materials, with options for lidding and carton lids to seal and access the contents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If substantially rigid plastic containers are used, then structural strength and stability are improved, but weight and recyclability worsen
Solution Approach 1:
The packaging system is divided into separate components: a rigid outer carton providing structural strength and a flexible inner bag containing the product. This segmentation allows each component to be optimized independently - the carton for strength and stability, the bag for lightness and flexibility.
Solution Approach 2:
The flexible inner bag is nested within the rigid outer carton, creating a composite packaging structure. The bag fits inside the carton, allowing the lightweight bag to benefit from the carton's structural support while maintaining overall system lightness.
2Strength
If substantially rigid plastic containers are used, then structural strength is improved, but manufacturing cost and environmental impact worsen
Solution Approach 1:
By separating the packaging into a reusable rigid carton and a disposable flexible bag, the system reduces the amount of expensive virgin plastic needed. The carton can be reused multiple times, amortizing its manufacturing cost, while the bag uses less material overall.
Solution Approach 2:
The system allows for recovery and reuse of the rigid carton while the flexible bag is discarded after use. This selective recovery strategy reduces overall manufacturing costs by reusing the more expensive component multiple times.
3Weight of moving object
If flexible bags are used, then weight and material usage are improved, but structural strength and mixing capability worsen
Solution Approach 1:
The flexible bag is nested within the rigid carton, which provides the structural strength that the bag lacks. The carton acts as a protective shell, enabling the lightweight bag to maintain its weight advantage while gaining structural support.
Solution Approach 2:
The rigid carton serves as an intermediary structure that provides structural support to the flexible bag. It mediates between the need for lightness (bag) and the need for strength (carton), allowing both requirements to be satisfied simultaneously.
4Loss of substance
If flexible bags are used, then material efficiency is improved, but ease of operation for residue removal and mixing worsens
Solution Approach 1:
The system segments the packaging functions: the flexible bag provides material efficiency while the rigid carton with its removable lid provides ease of operation for residue removal and mixing. The carton's large opening allows access to the bag contents.
5Reliability
If virgin plastic is used, then food safety regulations are satisfied, but cost and environmental sustainability worsen
Solution Approach 1:
The packaging system segments the food contact function (handled by the virgin plastic bag) from the structural function (handled by the recyclable carton). This allows compliance with food safety regulations using minimal virgin plastic while reducing overall material costs.
Solution Approach 2:
Virgin plastic is used only where required for food safety (the inner bag in contact with contents), while the outer carton can use recycled materials. This local application of material quality optimizes both compliance and cost.
Data Source
AI summary
The present disclosure, in one embodiment, relates to a packaging assembly for holding liquids, viscous material, or particulate material. The packaging assembly includes a carton having side and bottom walls. The packaging assembly also includes a self-supporting plastic liner that fits inside of the carton for containing liquids, viscous material, or particulate material. The liner has either a substantially circular or substantially oval cylindrical side wall, a closed bottom end characterized by a bottom wall formed integral with said side wall, and an open top end having an outwardly-projecting rim. The rim has a radially-extending flange portion, and a dependent skirt portion, wherein when the self-supporting plastic liner is inside of the carton, the radially extending flange portion supports the liner on at least a portion of the carton. A lidding material is provided to seal the plastic liner.