Foil-Lined Paper Fiber Trays Using Compressed-Air Lamination
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Solution Overview
Problem
Existing methods for lining trays with foil are complex, costly, and prone to issues like insufficient vacuum generation, foil misalignment, and unsightly appearance due to flush wall parts, especially with paper fiber-based materials.
Innovation Solution
The method involves using compressed air to blow the foil into the tray access opening, eliminating the need for vacuum generation and complex die coordination, while using a die to erect the sheet in a negative mold and integrating suctioning and heating to secure the foil on the tray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum extraction openings are provided in the lower tool and vacuum is generated below the tray to suction the foil, then the foil can be adhered to the tray, but the device complexity and costs increase due to complex coordination of die and vacuum generation means
Solution Approach 1:
The patent removes the vacuum generation system and extraction openings from the lower tool, extracting only the necessary function of foil adhesion through an alternative method. The die is designed to perform both shaping and foil adhesion functions, eliminating the need for separate vacuum extraction components.
Solution Approach 2:
The die is combined with the foil adhesion function, merging two operations into a single component. The die structure integrates the shaping function with the foil pressing function, allowing simultaneous tray formation and foil adhesion without requiring separate vacuum extraction equipment.
2Reliability
If vacuum extraction openings are provided in the lower tool, then foil adhesion is achieved, but production costs increase due to vacuum generating means and sealing measures
Solution Approach 1:
The patent extracts the vacuum generation system and sealing measures from the manufacturing process, eliminating the need for expensive vacuum pumps, extraction openings, and associated sealing components. The die structure alone performs the foil adhesion function.
Solution Approach 2:
The patent uses a simple, inexpensive die structure that can be easily manufactured and replaced if needed, replacing the expensive and complex vacuum generation system. The die performs the adhesion function through its pressing action without requiring costly vacuum equipment.
3Reliability
If air is extracted below the tray to generate vacuum, then foil suction is achieved, but secondary air suction occurs reducing vacuum effectiveness
Solution Approach 1:
The patent removes the vacuum generation system entirely, eliminating the problem of secondary air suction. The die pressing method achieves foil adhesion through direct mechanical pressure rather than vacuum, avoiding energy loss from sucking in secondary air.
4Device complexity
If wall parts of the tray abut against one another in a flush manner, then tray structure is simplified, but foil misalignment and holes occur resulting in unflattering appearance
Solution Approach 1:
The patent applies different functional zones to the die structure, with specific pressing surfaces designed to accommodate the flush wall parts and ensure proper foil alignment in critical areas. The die has localized pressing zones that adapt to the tray geometry to prevent foil misalignment at wall junctions.
Solution Approach 2:
The die is designed to pre-position and pre-press the foil against the tray walls before final tray formation, ensuring proper foil alignment at the flush wall parts early in the process. This preliminary action prevents foil misalignment and hole formation during subsequent operations.
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
This simplifies the process, reduces costs, and ensures a secure, adhesive-free lamination of the foil onto the tray, avoiding unsightly misalignment and holes, resulting in a reliable and cost-effective production method.
Implementation Method 1
compressed air release means (2a), which is formed to supply compressed air (6) to a side (34) of the foil (24) facing away from the tray (4) in order to blow the foil (24) into the access opening (20)
Implementation Method 2
suctioning means (29), which is formed to suction the foil (24) at points (24a)
Implementation Method 3
heating device (30) for heating the foil (24) in a region (24b) of the foil (24) located within a geometry of the collar (18)
Data Source
AI summary
A method for producing a shell lined with a film, in particular a shell for receiving food is provided, the method having the steps of: erecting an unfolded sheet of a paper fiber-based material in order to form a shell comprising a base, a lateral wall which has an upper edge and which consists of at least two lateral wall parts, wherein laterally adjacent lateral wall parts are designed to overlap with one another, and a collar which runs circumferentially on the upper edge and extends outwards therefrom and which defines an access opening, positioning the film above the access opening, heating the film, fixing the film on the collar, and supplying compressed air to the film side facing away from the shell in order to blow the film into the access opening in order to laminate the base and the lateral wall with the film.