Collapsible Meal Kit Tray for Airflow and Stable Cold-Pack Support
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Solution Overview
Problem
Existing meal kit shipping systems lack a means to securely support perishable items while maximizing air circulation for refrigeration and are complex to manufacture.
Innovation Solution
A collapsible tray system comprising a single blank that can be assembled from a bottom panel, side panels, and wings, with fold lines and perforations allowing for secure support of a bag and cold pack, and includes engagement tabs for securing within a shipping box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tray is designed to securely support meal kits and maximize air circulation, then refrigeration efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The tray is divided into multiple panels (front, rear, left side, right side panels) that can be folded from a single blank, allowing each segment to serve specific functions for support and air circulation while maintaining manufacturing simplicity through integrated construction
Solution Approach 2:
The tray incorporates collapsible sides with fold lines that allow the structure to transition between expanded (for support and circulation) and collapsed (for compact storage and shipping) states, resolving the contradiction between structural complexity and functional performance
2Reliability
If a collapsible tray is used to maximize air circulation, then refrigeration is improved, but structural strength may be compromised
Solution Approach 1:
The tray sides are designed with curved surfaces formed by fold lines at specific angles (e.g., 45 degrees), creating arch-like structures that provide structural strength while maintaining the collapsible geometry needed for air circulation and refrigeration effectiveness
Solution Approach 2:
The tray is pre-formed from a single blank with integrated fold lines and creases that create rigid geometric structures when assembled, providing necessary strength before the tray is placed into service, while still allowing collapse when needed
3Reliability
If engagement tabs are added to secure the tray in the shipping box, then stability is improved, but manufacturing complexity increases
Solution Approach 1:
The engagement tabs are integrated directly into the tray side panels as extensions of the same material blank, eliminating the need for separate components. The tabs are formed by folding and joining adjacent portions of the tray structure itself, providing secure positioning without increasing overall component count or manufacturing complexity
Data Source
AI summary
A method of assembling a meal kit tray from a single blank including a bottom panel, wherein the bottom panel is configured to support a bag containing refrigerated items and a cold pack, wherein the single blank further comprises a bottom panel; a side panel extending outwardly from at least a portion of the bottom panel, the side panel joined to the bottom panel along a first fold line defining a joint, wherein the first fold line is interrupted by at least one perforation line segment defining a standoff; and a wing extending outwardly from the side panel, the wing joined to the side panel along a second fold line defining a joint, the wing defining a free end; wherein the method comprises the steps of rotating the side panel upwardly about the first fold line to cause the standoff to separate from the side panel; and rotating the wing downwardly about the second fold line.