Folded Pan Lid Nesting for Shelf-Space Saving Packaging
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Solution Overview
Problem
The existing packaging methods for foil pans with lids do not allow for efficient nesting, leading to increased shelf space usage when stacked, as lids cannot be properly nested with the pans, which is not a preferred display method.
Innovation Solution
The solution involves designing pans and lids with specific configurations, including bi-lateral fold lines and a heat-shrinkable plastic band, allowing lids to be folded and securely nested within pans, and using different materials like aluminum and cardboard for improved heat retention and ease of folding/unfolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pans with lids are packaged by stacking, then lids can be properly included with pans, but shelf space is significantly increased
Solution Approach 1:
The lid is folded into a compact configuration that nests within the pan cavity. The folded lid's reduced dimensions allow it to fit inside the pan, enabling both components to be packaged together in a nested arrangement that minimizes shelf space while maintaining lid-pan association.
Solution Approach 2:
The lid is designed with fold lines that allow it to transition from a flat two-dimensional configuration to a three-dimensional folded configuration. This dimensional transformation enables the lid to fit within the pan's vertical cavity, converting a horizontal stacking problem into a vertical nesting solution.
2Temperature
If lids are made from thick rigid material, then heat retention is improved, but folding and nesting capability is reduced
Solution Approach 1:
The lid is constructed as a composite structure combining rigid heat-retentive material with flexible folding elements. The rigid portions provide thermal insulation while the flexible portions with fold lines enable the lid to be collapsed into a compact nesting configuration, achieving both heat retention and foldability.
Solution Approach 2:
The lid is divided into multiple segments or panels separated by fold lines. This segmentation allows the lid to be folded into a compact configuration for nesting while the individual segments maintain sufficient rigidity and material thickness to provide effective heat retention when assembled.
3Adaptability or versatility
If fold lines are added to lids, then nesting capability is improved, but structural strength is reduced
Solution Approach 1:
The lid exhibits local quality variations where fold lines are positioned to provide flexibility only in specific regions, while other areas maintain full structural strength. The fold lines are strategically located to enable nesting without compromising the lid's overall structural integrity or load-bearing capacity.
Solution Approach 2:
The fold lines are pre-formed during manufacturing to specific angles and depths that allow the lid to collapse into a compact configuration. These pre-formed folds are designed to distribute stress during folding, preventing structural failure while enabling easy nesting without requiring excessive force that would weaken the lid.
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 configuration enables efficient nesting and stacking of pans, saving shelf space while maintaining the ability to display products in a vertical orientation, reducing the likelihood of lid loss or damage, and enhancing heat retention through material selection.
Implementation Method 1
a band made out of a heat-shrinkable plastic may be placed around the outwardly-extending rim and lip of the nested pans
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 two bi-lateral fold lines, 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.