Interlocking Thermoform Trays for Long Medical Device Packaging
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Solution Overview
Problem
Conventional thermoforming machines are limited in producing packaging for long medical devices, often requiring custom machines that are cost-prohibitive or result in insufficient support when multiple trays are joined together, compromising packaging integrity.
Innovation Solution
The use of interlocking thermoform container bodies with cooperative interlocking structures and mating surfaces that align and engage to provide additional support and stability, allowing for the secure joining of multiple container bodies while minimizing material usage and tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple smaller trays are joined together to support longer medical devices, then the packaging can accommodate longer devices, but the support at the joining location becomes insufficient, compromising packaging integrity
Solution Approach 1:
The packaging system is divided into multiple modular thermoform trays that can be joined together. Each tray is a separate unit with standardized interlocking features, allowing them to be segmented for manufacturing while maintaining overall structural integrity when assembled into longer configurations.
Solution Approach 2:
Multiple trays are merged through interlocking structures that combine them into a unified assembly. The interlocking features (protrusions and recesses) create a merged structure where the trays work together as a single unit, providing continuous support along the entire length of the packaged medical device.
2Length of moving object
If custom thermoforming machines are used to produce packaging for long medical devices, then the packaging can be produced, but the equipment costs become prohibitive
Solution Approach 1:
Instead of requiring a single custom machine to produce long continuous trays, the system segments the production into multiple standard-length trays that can be manufactured on conventional equipment. This avoids the need for expensive custom thermoforming machines while achieving the same functional result.
Solution Approach 2:
The thermoform trays are designed with universal interlocking features that allow them to be used in various configurations (single tray, two trays joined, three trays joined, etc.). This multi-functionality means that standard equipment can produce trays that serve multiple purposes, eliminating the need for specialized custom machines.
3Length of moving object
If multiple trays are joined together to create longer packaging, then longer devices can be supported, but the complexity of the joining structure increases
Solution Approach 1:
The interlocking features are localized to specific areas of the trays (edges or ends) rather than requiring complex structures throughout. The majority of each tray remains simple and unmodified, with the joining complexity concentrated only in the interlocking zones, maintaining overall structural simplicity.
Solution Approach 2:
The interlocking structures use asymmetric male-female protrusion-recess pairs that provide strong mechanical connection with simple geometries. The asymmetric design allows for easy identification of correct orientation during assembly while maintaining structural simplicity and avoiding complex symmetric mechanisms.
Data Source
AI summary
A package for a product that contains a first and a second thermoform container body that are configured to support the product. The first container body includes a first outer wall extending along a side of the first container body and defining a first mating surface and a first interlocking structure proximate the first outer wall and including an outer surface. The second container body includes a second outer wall extending along a side of the second container body, an inner wall disposed inwardly of the second outer wall and defining a second mating surface, and a second interlocking structure intermediate the second outer wall and the inner wall. The first and second interlocking structures are configured to interlock with one another when the outer surface of the first interlocking structure is placed in facing engagement with the inner surface of the second interlocking structure.