Injection-Molded Rim Encapsulation for Hermetic Tray Sealing
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Solution Overview
Problem
Conventional paperboard trays are prone to gas and moisture leakage due to gaps and irregularities created during pressure forming, lack structural support, and are often flimsy, making them unsuitable for storing perishable goods as they can spoil prematurely and are difficult to carry and clean.
Innovation Solution
The development of a container with an encapsulated rim formed from injection-molded material, such as plastic, which provides a hermetic seal, structural support, and ease of handling by incorporating features like handles and internal dividers, while being reusable and washable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If pressure forming is used to create tray shape, then tray can be formed into desired shape, but gaps and irregularities are created that prevent hermetic sealing
Solution Approach 1:
The sealing function is segmented from the tray body by adding a separate encapsulated rim component. This rim is molded onto the tray flange and provides a smooth, continuous sealing surface that is independent of the tray's pressure-formed shape, thereby resolving the conflict between achieving desired tray shape and maintaining seal integrity.
Solution Approach 2:
The encapsulated rim acts as an intermediary element between the tray body and the sealing lid. It mediates the interface by providing a uniform, gap-free surface that enables hermetic sealing, while the tray body can maintain its pressure-formed shape with pleated or crimped corners without compromising the seal.
2Ease of manufacture
If paperboard material is used for tray, then tray can be formed easily, but tray lacks structural support and becomes flimsy
Solution Approach 1:
The tray system becomes a composite structure combining paperboard tray body with an encapsulated rim component. The paperboard provides ease of formation and molding, while the encapsulated rim adds structural strength and rigidity to the flange area, preventing buckling and maintaining tray integrity under load.
3Area of stationary object
If tray is made large for serving, then serving capacity increases, but tray becomes difficult to carry and handle
Solution Approach 1:
The flange area is segmented and encapsulated to create a distinct handling zone. The encapsulated rim provides a raised, defined edge that serves as a natural gripping area, making large trays easier to carry without reducing serving capacity.
4Device complexity
If conventional sealing methods are used, then sealing process is simple, but gaps allow gas and moisture to enter tray
Solution Approach 1:
The encapsulated rim is pre-formed and molded onto the tray flange before the sealing operation. This preliminary action creates a perfect sealing surface in advance, eliminating gaps and irregularities that would otherwise require complex sealing processes to address.
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 encapsulated rim ensures a hermetic seal, enhances the structural integrity of the tray, making it suitable for storing perishable goods, and allows for easy handling and cleaning, thereby extending the shelf life of contents and improving user convenience.
Implementation Method 1
The encapsulated rim ensures a tight seal, increases the tray's stiffness and stability, makes it easier to carry, and allows for reuse and washing, while maintaining the integrity of contents by preventing gas and moisture ingress.
Implementation Method 2
A tray may also be difficult to carry, due to its size and awkwardness. Especially large trays, whether circular or rectangular, easily shift masses placed thereon when the tray is carried from beneath. This in turn changes the balance of the tray and may cause the tray to be dropped. Similarly, many large trays are too flimsy to be carried by the edges, or lack a good gripping area along the edges.
Data Source
AI summary
A tray (100) or container (478) which may be hermetically sealed having a flange (116), rim (124), handle (258), rib, bottom surface (500), sidewall (114), or other portion that is encapsulated by or formed from injection-molded material.