Extruded Plastic Mesh Packaging Tray for Confectionery

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Solution Overview

Problem

Existing packaging solutions for confectionery are difficult to produce and expensive due to complex support structures requiring injection molds, and they lack shape stability, resource efficiency, and stackability.

Innovation Solution

A packaging shell with a form-stable support structure made from an extruded plastic network that is lightweight, allowing for reduced material usage, faster production cycles, and enhanced stackability, featuring a mesh structure that allows visibility and easy disposal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a complex support structure with ring-shaped elements and wire-like connectors is used, then the packaging can provide structural support for confectionery, but the manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvestructural supportVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The packaging shell is divided into a base portion and a support structure portion that can be separately formed and then assembled. The support structure includes multiple retaining elements that are segmented and arranged in a grid pattern, allowing for simplified manufacturing while maintaining structural support functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a simple, inexpensive thermoplastic material that can be easily molded into the support structure. The packaging is designed as a disposable item with a simple construction that eliminates the need for complex, expensive components while providing adequate support for the intended use.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If an injection mold is used to produce the support structure, then the packaging can be manufactured with precise dimensions, but the production cost increases

Engineering Contradiction:

Improvedimensional precisionVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The support structure is designed to be manufactured using simple molding techniques without requiring expensive injection molds. The thermoplastic material allows for cost-effective production methods that achieve sufficient dimensional precision for the packaging application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the manufacturing approach from precision injection molding to a simpler thermoplastic forming process. By adjusting parameters such as heating temperature and molding pressure, the process achieves adequate dimensional precision at lower cost.

Inventive Principle:

Principle #35Parameter changes

3Strength

If a solid, dense packaging structure is used, then the packaging provides high strength and stability, but the weight and material consumption increase

Engineering Contradiction:

Improvepackaging strengthVSAvoidpackaging weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The support structure features a grid pattern with openings between the retaining elements, creating a porous structure. This reduces material consumption and weight while maintaining adequate strength through the strategic arrangement of support elements that provide structural integrity where needed.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The support structure is segmented into multiple discrete retaining elements arranged in a grid, rather than using a solid continuous structure. This segmentation reduces material usage and weight while the distributed arrangement of elements maintains overall structural strength and stability.

Inventive Principle:

Principle #1Segmentation

4Strength

If a complex support structure is used, then the packaging can provide adequate support, but the production cycle time increases

Engineering Contradiction:

Improvestructural supportVSAvoidproduction cycle time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The support structure is segmented into multiple retaining elements that can be formed simultaneously in a single molding cycle. The base portion and support structure portion are designed to be manufactured in separate but parallel processes, reducing overall production cycle time while maintaining structural support functionality.

Inventive Principle:

Principle #1Segmentation

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 packaging shell achieves high shape stability with low weight, reduces energy consumption in production, allows for easy stacking and transportation, and offers improved disposal options while maintaining structural integrity and visibility of contents.

Implementation Method 1

heated to a temperature in which the elastic memory of the material is switched off so that the heated piece of material maintains a form given to it

Methodology Applied

Scientific EffectElastic memory: Elasticity

Implementation Method 2

heated to a temperature in which the elastic memory of the material is switched off so that the heated piece of material maintains a form given to it

Methodology Applied

Scientific EffectThermal deformation: Deformation

Data Source

PatentEP3530588B1Packaging tray, its use, and package including the tray

Publication Date: 2022.10.12 BACHMANN FORMING

Figure 1~2
Figure 3~5
Figure 6~7

AI summary

The packaging tray according to the invention comprises a dimensionally stable support structure (5) formed from an extruded plastic mesh (2), wherein the support structure (5) has one or more receiving compartments (6) each with a recess for receiving the goods to be packaged.