Container With Liner Forming Process
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Solution Overview
Problem
Existing container manufacturing processes are inefficient in forming containers with integrated liners for heating food products, particularly in high-volume production settings, as they require multiple steps and result in lower production rates compared to forming the base layer and attaching the liner separately.
Innovation Solution
A method and structure for forming a container using a blank with a central panel, foldable panels, and a denesting feature, where the blank is transformed into a base layer with a liner attached to its inner surface using air pressure and heat, allowing for rapid formation of containers with integrated liners without prior formation of the base layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the container is formed by first creating the base layer and then separately attaching the liner, then the manufacturing precision and structural integrity are improved, but the production rate decreases
Solution Approach 1:
The patent combines the base layer formation and liner attachment operations into a single integrated process step. The liner is positioned on the blank before forming, and both the base layer structure and liner attachment are achieved simultaneously during the forming operation, eliminating the need for separate attachment steps and thereby increasing production rate while maintaining structural integrity through proper design of the integrated process
2Manufacturing precision
If multiple manufacturing steps are used to form the container with liner, then the manufacturing precision is improved, but the production time increases
Solution Approach 1:
The liner is positioned and secured to the blank before the forming operation begins. This preliminary positioning ensures that the liner is already in place and properly aligned before the base layer is formed, eliminating the need for subsequent attachment steps and reducing overall production time while maintaining formation accuracy through the pre-planned positioning arrangement
3Reliability
If the liner is attached separately after base layer formation, then the reliability of attachment is improved, but the device complexity increases
Solution Approach 1:
The forming process itself serves the dual function of creating the base layer structure and attaching the liner simultaneously. The design of the integrated process allows the forming operation to inherently secure the liner through the formation actions, eliminating the need for separate attachment equipment or additional process steps, thereby reducing device complexity while maintaining attachment reliability through the unified process design
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases production rates, up to 200 trays per minute, by integrating the liner attachment directly into the container formation process, enhancing efficiency and reducing production time while maintaining recyclable materials and compatibility with oven heating.
Implementation Method 1
applying air pressure to a heated liner material and the construct to move the liner material toward the construct
Implementation Method 2
applying air pressure to a heated liner material and the construct to move the liner material toward the construct
Data Source
AI summary
A container for holding a food product. The container can comprise a base layer and a liner at least partially attached to an inner surface of the base layer, a flange comprising a central panel of the base layer, an opening extending in the central panel, and a sidewall comprising at least a panel foldably connected to the central panel along the opening.