Thermoformed Lids With Concave Channel Interruptions
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Solution Overview
Problem
Thermoformed plastic lids stick together during manufacturing and storage due to perfect engagement, causing manufacturing issues and reducing efficiency in storage and transportation, while existing solutions with convex external protrusions compromise aesthetics and uniformity.
Innovation Solution
The use of concave channels with interruptions on thermoformed lids provides stacking separation without visible external structures, allowing for greater vertical separation and reduced contact surface area, enabling more permutations and minimizing the likelihood of lids sticking together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If lids are made completely identical for perfect nesting, then storage and transportation efficiency is improved, but lids stick together causing manufacturing problems and scrap
Solution Approach 1:
The patent applies asymmetry by creating non-identical stacking surfaces on adjacent lids through varying lug positions, lug lengths, or recess configurations. This asymmetric design prevents perfect nesting while maintaining compact stacking, resolving the contradiction between storage efficiency and manufacturing reliability by ensuring lids do not stick together during production.
2Ease of operation
If convex external protrusions or lugs are added to prevent sticking, then separability and cooling efficiency are improved, but aesthetics and uniformity are compromised
Solution Approach 1:
The patent applies nesting by placing lugs and recesses on the top surface of lids that nest into corresponding features of adjacent lids. This nested configuration provides stacking separation and improved separability while maintaining a smooth, uniform external appearance, thus resolving the contradiction between ease of operation and aesthetic shape.
3Ease of operation
If vertical space between adjacent lids is increased for separability, then cooling efficiency and separability are improved, but storage and transportation efficiency is reduced
Solution Approach 1:
The patent applies partial action by creating minimal vertical spacing between lids through the lug-recess interface, which is sufficient to prevent sticking and aid separability without requiring excessive vertical space. This partial separation maintains compact stacking for efficient storage while providing enough clearance for cooling and separability operations.
Data Source
AI summary
A kit of thermoformed lids comprising a three lids which are substantially similar except for specific differences in four stacking areas located at the corners of the lids. Unlike prior art lids that use convex external lugs to provide separation during stacking, lids according to the present invention have stacking areas formed as interruptions in concave channels located along the peripheries of the lids, improving the appearance and uniformity of products comprising the lids.