Sheet Metal Gastro Container Height Extension With Thin-Wall Deep Drawing
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Solution Overview
Problem
Existing methods for producing gastro containers made of sheet metal, such as deep-drawing, are limited in achieving larger dimensions with thin walls, as they require thicker materials for larger sizes, which increases costs and complicates hygiene maintenance.
Innovation Solution
The method involves using a thin sheet metal with a thickness of 0.4 to 0.8 mm for deep-drawing essential contours, then making a separating cut to create an upper and lower container area, and inserting a container jacket to achieve desired height, while ensuring hygiene standards with rounded corners and edges, and optionally using a temperature-insulating plastic profile for double-walled designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If deep-drawing process is used to produce gastro containers with larger dimensions, then container height and depth increase, but wall thickness must be increased from 0.4-0.8 mm to 1.2-3 mm
Solution Approach 1:
The container is divided into two functional parts: a deep-drawn base portion (Gepresste Teil) providing structural integrity, and an added sheet metal jacket (Blattmetall-Mantel) providing height. This segmentation allows each part to be optimized independently - the base can be thin-walled while the overall container achieves greater height through the attached jacket portion.
2Volume of stationary object
If deep-drawing process is used for larger containers, then container capacity increases, but material cost increases due to thicker walls
Solution Approach 1:
The container structure is segmented into a deep-drawn base and an added sheet metal jacket. This allows the majority of the container volume to be achieved through the lightweight jacket rather than requiring uniformly thick walls throughout, significantly reducing total material consumption while maintaining large capacity.
Solution Approach 2:
The sheet metal jacket acts as a thin-film structure that provides the majority of the container's volume and capacity. This thin-film approach allows large volumes to be encased with minimal material, replacing the need for thick-walled construction that would be required if using only the deep-drawing process.
3Quantity of substance
If thin sheet metal is used for deep-drawing, then material cost decreases, but container height is limited to small dimensions
Solution Approach 1:
The container is segmented into a deep-drawn base portion made from thin sheet metal and an additional sheet metal jacket that extends the height. This segmentation allows the thin-walled construction to achieve greater overall height by combining the deep-drawn portion with the extended jacket, overcoming the height limitation of thin-walled deep-drawing alone.
4Strength
If thicker material is used for large containers, then structural strength increases, but hygiene maintenance becomes more difficult
Solution Approach 1:
The sheet metal jacket functions as a thin-film structure that can be easily cleaned and maintained for hygiene purposes. The smooth, continuous surface of the thin-walled jacket is more amenable to thorough cleaning and sanitization compared to thick-walled constructions with complex internal structures, while still providing adequate structural strength for its intended function.
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 approach allows for the production of gastro containers with large overall heights or depths while meeting high hygiene requirements and reducing material costs, enabling flexible and cost-effective production of containers suitable for various applications, including community catering and refrigeration.
Implementation Method 1
Deep-drawing essential contours
Implementation Method 2
The container jacket and the edges of the upper and lower container area are expediently welded to one another
Implementation Method 3
a temperature-insulating plastic profile is advantageously used, which has a very low heat transfer coefficient
Data Source
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AI summary
The invention relates to a method for producing a gastronomy container and to a single-walled or double-walled gastronomy container made of sheet metal. In order to achieve a cost reduction in the production method of such containers and also be able to implement the height of the containers in different dimensions, first a container bowl or pan is produced from a thin metal sheet having a thickness of 0.4 to 1.0 mm by deep drawing. Because deep drawing has limits in terms of the dimensions when using thin metal sheets, a horizontally circumferential separating cut is carried out on the container bowl. In a further step, a container jacket having almost any random height can thus be inserted between the parts separated by means of the separating cut and be welded on, for example. The double-walled form of such a container is further improved by separating the upper support edge of the container facing the inside wall into two parts, and by providing said two parts with an interruption of the thermal conductivity from the inside out and vice versa by means of a profiled connecting section made of plastic material.