Double-Walled Paper Container Nested Sleeve Design
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Solution Overview
Problem
Existing insulated containers are complex and costly to manufacture due to the need for separate manufacturing steps and complex features like ribs and ridges, which increase production complexity and cost.
Innovation Solution
A double-walled container design featuring an inner and outer sleeve with a smooth-walled configuration, where the inner sleeve is positioned within the outer sleeve, creating a cavity for thermal insulation, and both sleeves are optionally tapered and made of paper material to simplify manufacturing and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ribs, ridges, or complex stiffening features are added to provide structural support and insulation, then thermal insulation performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The container is divided into two separate sleeves (inner and outer) that are manufactured independently and then assembled. This segmentation allows each sleeve to be produced using simple, cost-effective processes without complex features, while the combined structure provides the necessary insulation and structural support.
Solution Approach 2:
The inner sleeve is nested within the outer sleeve, creating a double-walled structure. This nesting arrangement provides thermal insulation through the air gap between sleeves while maintaining manufacturing simplicity, as each sleeve can be produced using basic forming processes without requiring complex ribs or ridges.
2Adaptability or versatility
If multiple separate parts are used to form the container, then functional features (insulation, stacking, stiffening) are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The double-walled structure serves multiple functions simultaneously: the air gap between sleeves provides thermal insulation, the tapered geometry enables stacking, and the overall structure provides structural support. This multi-functionality is achieved without requiring separate components for each function, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
Multiple functional requirements (insulation, stacking capability, structural support) are merged into a single integrated design approach. The tapered double-walled structure combines these functions without requiring separate ribs, ridges, or complex assembly steps, simplifying the manufacturing process while maintaining versatility.
3Ease of operation
If a tapered geometry is used for both sleeves, then ease of stacking and unstacking is improved, but manufacturing precision requirements increase
Solution Approach 1:
The taper angle is optimized to provide sufficient clearance for easy stacking and unstacking while remaining within the capabilities of standard manufacturing processes. By carefully selecting the taper angle parameter, the design achieves ease of operation without requiring excessive manufacturing precision that would increase production costs.
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
The design enhances thermal insulation while streamlining the manufacturing process, reducing material costs and complexity, and allows for easier stacking and unstacking of containers.
Implementation Method 1
The inner surface of the outer sleeve sidewall is spaced outwardly from the outer surface of the inner sleeve sidewall. Thus, a sidewall cavity may be formed between the inner sleeve sidewall and the outer sleeve sidewall.
Data Source
AI summary
A double-walled container including an inner sleeve, an outer sleeve and a base is provided. The inner sleeve is positioned within the outer sleeve. A sidewall cavity may be formed between an inner sleeve sidewall and an outer sleeve sidewall. The lower end of the outer sleeve forms an elongated loop located below a lowermost edge of the inner sleeve. A flange may extend from the elongated loop upwardly above the lowermost edge of the inner sleeve and is attached to the inner sleeve. The elongated loop may form a loop cavity. The loop cavity may be in fluid communication with the sidewall cavity.