Methods for manufacturing serving tray with inner raised surface incorporating thermoplastic polyurethane
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Solution Overview
Problem
Current serving trays with textured surfaces are not completely foolproof against items sliding or tipping due to condensation, and rubber or cork inserts degrade over time, reducing durability and increasing costs.
Innovation Solution
A serving tray with a top surface and bottom surface made of synthetic materials, featuring a textured relief integrally bonded with thermoplastic polyurethane (TPU) and an inner support structure with a protrusion around the circumference, designed to maintain items upright even when tilted, using a combination of glass fiber sheets and polycarbonate resin in compression or injection molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a textured surface is formed on the tray to prevent items from sliding, then the anti-slip performance is improved, but condensation can make the textured surface slick and reduce effectiveness
Solution Approach 1:
The patent uses a composite structure combining a rigid tray body (polycarbonate resin) with a flexible TPU insert layer. The TPU material provides consistent friction properties that maintain anti-slip effectiveness even when condensation is present, as its elastic nature allows it to conform to and grip objects regardless of moisture levels.
Solution Approach 2:
The textured surface is specifically engineered with asymmetric protrusions and recesses that create mechanical interlocking with objects. This localized texturing on the TPU insert provides enhanced grip zones that maintain friction properties despite condensation, as the asymmetric geometry creates physical barriers that prevent sliding.
2Reliability
If rubber or cork inserts are used to provide friction and prevent sliding, then the anti-slip performance is improved, but the inserts break down over time due to repeated moisture exposure
Solution Approach 1:
The patent replaces traditional rubber or cork inserts with thermoplastic polyurethane (TPU) material that is integrally bonded to the tray body. TPU exhibits superior resistance to moisture degradation while maintaining flexible friction properties, eliminating the breakdown issue associated with traditional insert materials and extending tray lifespan.
Solution Approach 2:
The TPU insert is integrally bonded to the tray body, creating a unified structure where the insert and tray become one piece. This merging eliminates the separation and degradation issues of loose inserts, as the TPU is permanently attached and protected from complete environmental exposure while maintaining surface friction properties.
3Reliability
If an inner support structure with protrusion is added to maintain items upright, then the stability is improved, but the device complexity increases
Solution Approach 1:
The tray structure is segmented into distinct functional components: the rigid polycarbonate tray body for structural support, the flexible TPU insert for friction, and the asymmetric protrusion elements for stability. This segmentation allows each component to be optimized independently while maintaining overall simplicity through modular integration.
Solution Approach 2:
The inner support structure features asymmetric protrusions strategically positioned to provide upward facing edges that cradle objects. These localized structural features are integrated directly into the molding process, adding minimal complexity while providing targeted stability support where needed rather than requiring comprehensive structural reinforcement throughout the entire tray.
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 tray effectively prevents items from sliding or tipping at angles up to 45 degrees and maintains durability by resisting condensation and moisture, allowing for efficient stacking and easy handling while extending the tray's lifespan.
Implementation Method 1
layering at least two layers of randomly distributed and continuous glass fiber filament sheets on top of the insert, and then layering at least two layers of crisscrossed interlocking glass fiber sheets with a chemical binder on top of the insert. Next, an interstitial layer of polycarbonate resin is disposed between the at least two layers of crisscrossed interlocking glass fiber sheets with a chemical binder. The insert, the least two layers of randomly distributed and continuous glass fiber filament sheets, the at least two layers of crisscrossed interlocking glass fiber sheets with a chemical binder, and the interstitial layer of polycarbonate resin are then compressed against the lower tool portion
Implementation Method 2
The invention also includes an improvement in a method of making a friction enhanced tray in an injection molding apparatus. The method includes placing an insert on a first half of a mold of the injection molding apparatus, enclosing the insert by bringing a second half of the mold against the first half of the mold, the first and second halves of the mold forming a completed mold tool, and then injecting a liquid interstitial resin into the completed mold tool.
Implementation Method 3
The textured relief is made from an insert that is integrally bonded with the at least one synthetic material... the tray effectively prevents items from sliding or tipping at angles up to 45 degrees
Implementation Method 4
The insert, the least two layers of randomly distributed and continuous glass fiber filament sheets, the at least two layers of crisscrossed interlocking glass fiber sheets with a chemical binder, and the interstitial layer of polycarbonate resin are then compressed against the lower tool portion
Implementation Method 5
The tray further includes a shaped smooth boundary portion that is located between the textured surface and the inner support structure on the raised edge on the top surface... made from a number of synthetic layers including at least two layers of randomly distributed and continuous glass fiber filament sheets, at least two layers of crisscrossed interlocking glass fiber sheets with a chemical binder, and an interstitial layer of polycarbonate resin
Data Source
AI summary
A serving tray comprised of at least one synthetic material and an insert which provides a non-slip top surface of the serving tray. The textured relief is preferably made of thermoplastic polyurethane (TPU) which allows a glass or other item to be placed on the serving tray without the item sliding or slipping while the tray is in motion. As the tray is being fabricated, the TPU is mechanically bonded with the top surface of the tray while a textured relief is simultaneously defined into the top surface. The textured relief provides adequate frictional force to an item being placed on the tray so as to substantially prevent its lateral movement. The tray also includes an inner support structure disposed on its inner surface. The inner support structure provides an upward facing edge which allows a plurality of trays to be easily and efficiently stacked or nested on one another.