Molded Fiber Tub with Projections for Automated Stacking
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Solution Overview
Problem
Current manufacturing processes for thermoformed blister packs, particularly those using renewable materials like paperboard and plant fibers, face limitations in design and functionality due to draft angle requirements, leading to difficulties in automated processing and assembly, and environmental concerns regarding plastic use are driving the need for cost-effective, efficient, and precision-manufacturable packaging solutions.
Innovation Solution
The development of a consumer product package featuring a tub with a base and perimeter wall that includes projections and recessed portions to facilitate easy stacking and automated processing, made from renewable fiber materials, with a laminate structure combining cellulose-based substrates and polymeric layers for strength and sealing, allowing for non-perpendicular angles and reverse draft angles to enhance manufacturability and environmental sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional thermoformed plastic packaging is used, then manufacturing speed and volume production are improved, but environmental sustainability deteriorates
Solution Approach 1:
The patent changes the material parameter from traditional plastic to molded fiber, fundamentally altering the environmental properties while maintaining manufacturing efficiency. The fiber material is processed through molded pulp technology that enables high-speed production comparable to traditional thermoforming, thus resolving the contradiction between productivity and environmental sustainability
Solution Approach 2:
The patent employs composite fiber materials made from recycled or renewable sources, combining multiple fiber types and treatments to achieve both environmental sustainability and manufacturing performance. The composite structure allows the material to be molded efficiently while maintaining structural integrity and reducing environmental impact
2Ease of manufacture
If multiple draft angles are incorporated for mold removal, then ease of manufacture is improved, but automated feeding and stacking deteriorates
Solution Approach 1:
The patent segments the draft angle requirements by applying different draft angles to different portions of the package structure. Specifically, the bottom portion has a first draft angle optimized for mold removal, while the side walls have a second draft angle that provides a clearance gap, enabling both easy manufacture and automated handling
Solution Approach 2:
The patent applies local quality by giving different regions of the package different geometric properties. The bottom surface has a draft angle for mold release, while the side walls have reduced draft angles or vertical sections that create clearance gaps, allowing each region to serve its specific function in the manufacturing and automation process
3Stability of the object's composition
If reverse draft angles are used to prevent sticking, then stacking ability is improved, but manufacturing complexity deteriorates
Solution Approach 1:
The patent applies partial reverse draft angles only where necessary to prevent stacking adhesion, rather than applying them to the entire package structure. The reverse draft angle is strategically positioned at the bottom portion to create a clearance gap that prevents sticking during stacking, while the rest of the structure maintains simpler geometry, thus balancing stacking ability with manufacturing complexity
Data Source
AI summary
A consumer product package comprising a tub comprising a base and a perimeter wall defining a cavity, the base comprising at least two projections extending from the base within the cavity, the at least two projections spaced apart from the perimeter wall; and a consumer product disposed within the cavity such that each of the at least two projections define a recessed portion to receive the consumer product, wherein the base comprises a secondary projection having a height different than a height of each of the at least two projections, the secondary projection free of contact from the consumer product.