Folded Paper Container with Hinged Closure
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Solution Overview
Problem
Existing paper-based containers for food products face limitations in vertical extension, rigidity, and manufacturing complexity, leading to inefficiencies in product support and closure mechanisms, which increase costs and reduce flexibility in use.
Innovation Solution
A container made from a single flat sheet of paper material, comprising multiple hollow elements with inclined lateral walls and flanges, allowing for high vertical development and easy closure through a hinged panel system, enhancing structural strength and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple distinct baking cups are engaged on a perforated sheet, then products with predetermined height can be housed, but manufacturing complexity increases and costs rise
Solution Approach 1:
The container is divided into multiple hollow elements (compartments) that are integrally formed from a single flat sheet through folding. Each hollow element can independently house a product, providing segmentation functionality without requiring separate assembled pieces, thus reducing manufacturing complexity while maintaining product support capability
Solution Approach 2:
Multiple hollow elements that would traditionally be separate components are merged into a single integrally formed structure. The folding process combines multiple compartments into one unified container made from a single flat sheet, eliminating the need for assembly of multiple distinct parts and reducing manufacturing steps
2Ease of manufacture
If cups are made by stamping a single flat sheet, then manufacturing is simplified, but vertical extension is limited
Solution Approach 1:
The container design transitions from a two-dimensional stamped sheet to a three-dimensional folded structure. By folding the flat sheet vertically to create hollow elements with lateral walls extending from the base, the container achieves significant vertical extension while still being manufactured from a single flat sheet through folding operations
3Ease of manufacture
If a single flat sheet is folded into multiple hollow elements, then manufacturing is simplified, but structural rigidity decreases
Solution Approach 1:
The flat sheet is segmented into multiple hollow elements through folding, where each element has its own base and lateral walls. This segmentation creates a three-dimensional structure that distributes mechanical loads across multiple compartments, enhancing overall structural rigidity compared to a single flat panel
Solution Approach 2:
The folding process creates curved and angled surfaces in the lateral walls of each hollow element. These non-flat geometric features increase structural rigidity by distributing stress more effectively than flat surfaces, while still being formed from a single flat sheet through folding operations
4Ease of manufacture
If containers lack closure capability, then manufacturing is simpler, but product protection is compromised
Solution Approach 1:
The closure function is merged into the container structure itself through the panel system. Panels are integrally formed with the hollow elements and can be folded over to close the container, eliminating the need for separate closure components while maintaining product protection capability
Solution Approach 2:
The panels are designed to be movable between open and closed positions through folding actions. This dynamic capability allows the container to transition from an open state for product insertion to a closed state for product protection, all while being formed from a single flat sheet without additional closure components
Data Source
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AI summary
The present invention refers to a container obtained by folding a single flat blank of paper sheet material. The container comprises a plurality of hollow elements joined to each other in one piece, each of them comprises a base and a lateral wall; the lateral wall emerges from the base and defines with this latter a seat configured to receive at least one product. Moreover, the present invention refers to a process of making said container and to a use of the same, and also to a package and process of making the same.