Integrated Tray Ridge Packaging for Unified Outer Surface
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Solution Overview
Problem
Existing packages for consumer products are susceptible to degradation due to exposure to ambient air, leading to issues with product preservation and presentation.
Innovation Solution
A package design featuring a first tray with a ridge that integrates seamlessly with the outer container, forming a unified outer surface and allowing for removable trays, which can house consumer products and accessory items, while maintaining a cohesive appearance and protecting against air exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the package uses a traditional tray design without an integrated ridge, then the manufacturing process is simpler, but the outer surface of the assembled package is not unified and the tray may shift within the container
Solution Approach 1:
The ridge is integrated directly into the tray structure during the thermoforming process, merging two previously separate components (tray and ridge) into a single unified structure. This integration ensures the ridge and tray move as one piece, preventing shifting while maintaining a unified outer surface when the container is closed.
Solution Approach 2:
The ridge is formed as part of the tray during the initial thermoforming process, before the tray is placed into the container. This preliminary formation of the ridge structure ensures proper positioning and prevents subsequent shifting, while also ensuring the ridge will be visible and flush with the container exterior when assembled.
2Ease of operation
If the tray is made removable for reuse and recycling, then ease of operation improves, but the risk of product exposure to ambient air increases during handling
Solution Approach 1:
The package design allows dynamic transition between closed and open states. The tray can be easily removed from the container for recycling or reuse, but when the container is closed, the integrated ridge structure ensures the tray remains securely positioned, minimizing air exposure during normal storage and transport conditions.
3Reliability
If the ridge is integrated into the tray structure, then the outer surface is unified and product protection is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The thermoforming process automatically forms the ridge as an integral part of the tray structure. The heating and forming processes create the ridge geometry through material deformation and cooling, without requiring separate assembly steps or additional fastening mechanisms. This self-forming approach reduces manufacturing precision requirements compared to mechanical assembly methods.
Data Source
AI summary
The method includes forming a first tray with a first top surface, the first tray including first sidewalls that extend vertically downward from the first top surface, the first tray defining a first ridge extending horizontally away from the first sidewalls, and configuring an outer container to selectively contain the first tray when the outer container is in a closed position, a first outer surface of the first ridge forming part of an overall outer surface of the assembled package when the outer container is in a closed position.