Stackable Egg Tray with Rotating Flapper to Prevent Air Lock
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Solution Overview
Problem
Existing thermoformed trays stacked using vacuum molding techniques often experience friction and air lock issues, leading to jamming in automated packaging and labeling apparatuses, which results in productivity losses and potential damage to equipment.
Innovation Solution
The trays are designed with spacing means, such as stoppers with negative angles, to maintain distance between neighboring trays, preventing interlocking and allowing easy denesting, and are manufactured using thermoplastic materials like polyethylene terephthalate with ribbed cavities for egg protection and ventilation to prevent air locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If trays are stacked one into the other using vacuum molding techniques, then storage space is optimized and trays can be neatly organized, but friction and air lock are created between neighboring trays causing interlocking
Solution Approach 1:
The tray is divided into a body portion and a separate flapper portion that can rotate independently. The flapper acts as a movable segment that prevents interlocking by breaking the continuous contact surface between stacked trays, allowing easy removal while maintaining compact storage.
Solution Approach 2:
The flapper is designed to be movable rather than fixed, capable of rotating between a horizontal position (when tray is inserted) and a vertical position (when tray is removed). This dynamic element prevents air lock and friction by changing the contact geometry during the stacking and unstacking operations.
2Productivity
If trays are stacked tightly one into the other, then storage efficiency is improved, but air lock and friction cause jamming in automated packaging apparatus
Solution Approach 1:
The movable flapper creates a dynamic gap mechanism that prevents air lock formation during stacking. When the flapper rotates to the vertical position, it creates a pressure equalization path that eliminates the vacuum effect causing air lock, ensuring reliable automated handling without jamming.
Solution Approach 2:
The flapper acts as an intermediary element between the tray body and the tray above it. By rotating the flapper, it mediates the interaction between stacked trays, preventing direct contact that causes friction and air lock, thus ensuring smooth operation of automated packaging apparatus.
3Stability of the object's composition
If trays are designed with interlocking system in close position, then accidental opening is prevented, but removal of trays from stack becomes difficult
Solution Approach 1:
The flapper provides a dynamic solution that changes state based on operation type: in the horizontal position, it engages with the tray above to maintain closure integrity; when rotated to vertical position, it disengages to facilitate easy tray removal from the stack, resolving the contradiction between stability and ease of operation.
Solution Approach 2:
By separating the closure function (performed by the flapper in horizontal position) from the stacking function (performed by the flapper in vertical position), the design allows the tray to provide secure closure during transport while enabling easy denesting when the flapper is rotated, thus resolving the contradiction between stability and ease of operation.
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 solution enables trays to be stacked and easily removed without jamming, ensuring the integrity of eggs during packaging and transport, while facilitating automated processing and reducing the risk of accidental opening.
Implementation Method 1
spacing means to keep, in a stack of trays, the top portion and the bottom portion of neighboring trays at distance from each other to thereby prevent interlocking therebetween
Implementation Method 2
the air between trays is in fluid communication with the air surrounding a stack of trays to avoid pneumatic interlocking of trays
Data Source
AI summary
A stackable tray obtained by vacuum molding of a sheet of plastic material, said tray comprising, in open position: a) a top and a bottom; b) at least one receiving cavity opened upwardly; c) spacing means to keep, in a stack of trays, the top portion and the bottom portion of neighboring trays at distance from each other to thereby prevent interlocking. A stack of said trays and a method using said trays.