Folded Pan Covers with Repulpable Barriers for Recyclable Packaging
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Solution Overview
Problem
Existing foil pan lids are not recyclable due to a significant aluminum content, which cannot be easily separated by consumers, leading to disposal issues.
Innovation Solution
A cardboard-based lid with a repulpable barrier substrate coating, accounting for 10% or less of the lid's mass, providing a water, oil, and grease barrier, and a thin cardboard surface for heat retention, allowing the lid to be folded and secured within the pan, ensuring recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum coating is applied to provide moisture and heat barrier, then barrier performance is improved, but recyclability deteriorates
Solution Approach 1:
The patent extracts the aluminum coating from the lid structure, replacing it with a paper-based material that provides equivalent barrier performance. This allows the lid to be fully recyclable with paper while maintaining the necessary moisture and heat barrier properties through alternative materials and design.
Solution Approach 2:
The patent changes the material parameters from aluminum-based to paper-based, fundamentally altering the composition to enable recyclability. The paper material is treated or engineered to achieve the barrier properties previously provided by aluminum, thus changing the physical and chemical parameters of the lid material.
2Reliability
If lid is made flat for use, then coverage and protection are improved, but storage efficiency deteriorates
Solution Approach 1:
The patent designs the lid to fold into a compact configuration that nests within the pan cavity. The folded lid fits inside the pan, allowing efficient storage and stacking without requiring additional space, while still providing full coverage when unfolded and placed on the pan.
Solution Approach 2:
The patent transforms the lid from a two-dimensional flat structure into a three-dimensional folded configuration that utilizes the vertical space within the pan cavity. This dimensional transformation allows the lid to be stored compactly while maintaining its full protective function when deployed.
3Volume of moving object
If folded configuration is implemented for storage, then storage efficiency is improved, but structural complexity deteriorates
Solution Approach 1:
The patent divides the lid into multiple panels or sections that can be folded relative to each other. These segmented sections are connected through creases or fold lines, allowing the lid to collapse into a compact form while maintaining structural integrity and ease of manufacture through simple geometric divisions.
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 recyclable lids that maintain heat retention and moisture barrier properties while being easily foldable and stackable, addressing the non-recyclability issue of traditional aluminum-coated lids.
Implementation Method 1
a first surface being coated with a repulpable barrier substrate defined to provide a water, oil, and grease barrier
Implementation Method 2
each lid having at least one bi-lateral fold line across the lid, such that the lid is configurable into a folded configuration
Data Source
AI summary
There is provided a packaged pan and lid that includes at least two nested pans and at least two lids. Each lid has at least a bi-lateral fold line, such that the lid is configurable into a folded configuration and removable secured within a well of a corresponding pan. The lid being removable from the well and unfolded to a substantially flat configuration. The lid may then be placed on the rim of the pan, such that a lip of the pan can be bent over the edge of the lid. Each one of the lids is configured out of a cardboard material and includes a first surface coated with a repulpable barrier defined to provide a water, oil, and grease barrier, and wherein a second surface which is opposed to the first surface maintains a cardboard finish configured with an area of indicia.