Expandable Paperboard Mesh Tray for Food Support
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Solution Overview
Problem
Existing pizza delivery cartons fail to keep pizza crust dry and crisp, and fresh produce dry and airy during delivery, as they are not economically viable, non-biodegradable, and inefficient in maintaining temperature and preventing ethylene gas buildup.
Innovation Solution
A biodegradable paperboard mesh support tray with varying mesh patterns and strand heights, printed with food-grade inks, that elevates pizza and produce off the carton base, enhancing air circulation and temperature retention while being cost-effective and widely distributable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an additional plastic tray with protruding ribs is used to elevate pizza, then air circulation is improved, but manufacturing cost increases and biodegradability is lost
Solution Approach 1:
The patent uses a paperboard mesh tray with interconnected apertures that allow air circulation while maintaining structural integrity. The mesh structure provides porosity for air flow without requiring additional plastic components, resolving the contradiction between air circulation and manufacturing cost/biodegradability.
Solution Approach 2:
The patent employs a composite paperboard structure combining different layers and mesh patterns to achieve both air circulation and structural support functions previously requiring separate plastic components, reducing manufacturing complexity and cost.
2Ease of operation
If an aluminum tray with pin hole air vents is used, then air circulation is improved, but manufacturing cost increases and biodegradability is lost
Solution Approach 1:
The paperboard mesh tray inherently provides air circulation through its porous mesh structure, eliminating the need for metal trays with pin holes. This resolves the contradiction by achieving air circulation through a biodegradable, cost-effective material.
Solution Approach 2:
The patent uses a disposable paperboard mesh tray that is inexpensive to manufacture and fully biodegradable, replacing expensive metal or plastic alternatives while maintaining the air circulation function throughout the delivery process.
3Stability of the object's composition
If a plastic clamshell is used for fresh produce, then containment is improved, but air circulation is insufficient and ethylene gas dissipation is poor
Solution Approach 1:
The paperboard mesh tray provides both containment for fresh produce and superior air circulation through its open mesh structure. The interconnected apertures allow air flow and ethylene gas dissipation while maintaining product containment, resolving the contradiction between containment and air circulation.
Solution Approach 2:
The mesh structure segments the tray surface into numerous small apertures that collectively provide extensive air circulation pathways while maintaining overall containment, allowing ethylene gas to escape while keeping produce contained.
4Ease of manufacture
If paperboard is used for the tray, then biodegradability and cost-effectiveness are improved, but structural strength may be insufficient
Solution Approach 1:
The patent uses multi-layer composite paperboard construction with different densities and properties combined to achieve the required structural strength while maintaining biodegradability and cost-effectiveness. The composite structure provides enhanced load-bearing capacity compared to single-layer paperboard.
Solution Approach 2:
The mesh structure incorporates curved and angled strands that interlock to distribute loads more effectively, enhancing the structural strength of the paperboard material without adding significant cost or compromising biodegradability.
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 paperboard mesh tray effectively keeps pizza crust dry and produce fresh by isolating it from juices and heat, maintaining temperature, and preventing ethylene gas buildup, while being economically viable and environmentally friendly.
Implementation Method 1
The mesh provides for increased air flow which just the clamshell base or paper diaper inserts do not
Implementation Method 2
A biodegradable paperboard mesh support tray with varying mesh patterns and strand heights
Implementation Method 3
the mesh traps the warm air to maintain temperature
Implementation Method 4
the elevation of the mesh off the clamshell floor allow free circulation of air, assisting in the dissipation of ethylene gases
Data Source
AI summary
A food support tray comprised of an expanded paperboard mesh tray insert for a delivery carton such as a pizza carton or a fresh produce clamshell. The expanded paperboard mesh is adapted for supporting pizza or other food items on the bond peaks of the expanded mesh, thus isolating the food item from oil and juices that could make the fresh food item turn soggy.