Disposable Tray with Variable-Height Sidewalls for Divider Strength
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Solution Overview
Problem
Disposable trays with compartmental dividers are weakened, leading to reduced strength, flush-fill volume, and inhibited access to contents, as existing techniques have been unsatisfactory in addressing these issues.
Innovation Solution
A disposable tray design featuring a perimeter wall with opposing first and second sidewalls of varying heights, a divider wall that intersects the second sidewalls at their maximum height, and a return flange, which increases the second sidewall height by at least 12% for enhanced strength without compromising access or fill volume, made from materials like polystyrene foam, molded fiber, or aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If compartmental dividers are added to trays to keep food items separate, then item separation is improved, but tray strength is worsened due to reduced sidewall height in the divider area
Solution Approach 1:
The patent applies local quality by creating a reinforced region at the intersection of the divider wall and sidewall. The sidewall height is increased locally at this critical intersection point, while other areas maintain their original dimensions. This localized reinforcement strengthens the tray at the most vulnerable point without compromising the overall lightweight design or the divider's ability to separate items.
2Strength
If techniques are used to strengthen trays having dividers, then tray strength is improved, but flush-fill volume is reduced
Solution Approach 1:
The reinforcement is applied locally only at the divider-sidewall intersection, rather than uniformly across the entire tray. This localized approach provides the necessary strength enhancement at the critical weak point while preserving the maximum possible flush-fill volume in the main tray body and compartments.
Solution Approach 2:
The patent addresses the strength issue by adding height in the vertical dimension at the critical intersection point, rather than increasing the horizontal dimensions that would reduce fill volume. This dimensional approach allows strength enhancement without compromising the tray's capacity.
3Strength
If techniques are used to strengthen trays having dividers, then tray strength is improved, but access to contents is inhibited
Solution Approach 1:
The reinforcement is localized to the divider-sidewall intersection area, leaving the rest of the sidewalls and tray openings unchanged. This ensures that access pathways and opening areas maintain their original accessibility, while only the specific reinforced region gains additional strength.
Data Source
AI summary
Disposable tray includes a base and a perimeter wall. The perimeter wall extends upwardly from the base to define an interior. The perimeter wall includes a set of opposing first sidewalls and a set of opposing second sidewalls. Each of the opposing first sidewalls having a first maximum height above the base and each of the opposing second sidewalls having a second maximum height above the base. The tray further includes a divider wall extending upwardly from the base. The divider wall extends between the set of opposing second sidewalls to define a plurality of compartments. The divider wall intersects each of the opposing second sidewalls proximate the second maximum height. The second maximum height is greater than the first maximum height.