Method and assembly group for manufacturing trays
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Solution Overview
Problem
The existing methods for manufacturing meal trays are difficult to automate due to constraints in container and tray sizes, making it challenging to vary the type of meal tray and produce large quantities efficiently.
Innovation Solution
A method and assembly group that allows for the easy variation of meal tray types and automates the manufacturing process along a production line, using a modular system with interchangeable components for containers and trays made of compostable cellulose-based materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard sizes of containers and trays are used, then the manufacturing process is simpler, but the adaptability to different requirements is reduced
Solution Approach 1:
The system is divided into modular components: interchangeable container sets (with different sizes and shapes), interchangeable tray sets, and configurable sealing systems. Each container and tray is designed as a standardized module that can be combined in various configurations, enabling both easy manufacturing and high adaptability to different meal requirements.
Solution Approach 2:
The interchangeable container sets and tray sets are designed with universal interfaces and standardized dimensions that allow the same basic components to serve multiple functions. A single container mold can produce various container types, and trays can accommodate different container arrangements, achieving multi-functionality while maintaining manufacturing simplicity.
2Adaptability or versatility
If customised solutions are used to vary meal tray types, then the adaptability is improved, but the productivity and automation capability are reduced
Solution Approach 1:
The system employs dynamic reconfigurability through interchangeable component sets. Rather than custom-building each tray variation, the system dynamically adapts by swapping standardized container and tray modules on the production line, maintaining high productivity while achieving the adaptability of customized solutions.
Solution Approach 2:
The system achieves variety by changing parameters of standardized components - different container sizes, shapes, and arrangements on trays - rather than creating entirely custom designs. This allows automated production to handle variations by adjusting module combinations rather than retooling for each configuration.
3Reliability
If individual filling and sealing of containers is performed, then the sealing quality is improved, but the automation difficulty increases
Solution Approach 1:
The system merges the filling and sealing operations into an integrated automated process. Containers are filled and sealed in sequence on the production line using coordinated automated equipment, maintaining sealing quality while enabling full automation. The standardized container designs with consistent opening positions facilitate this integrated approach.
Data Source
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AI summary
Method and assembly group (9) for manufacturing a meal tray (1); the assembly group (9) having a base (10), a nest tray holder (11) and a nest tray (12) which are coupled in a releasable way to each other; said assembly group being configured to house a plurality of containers (2; 2I, 2II, 2III); the method comprising the step of sealing each tray (2; 2I; 2II; 2III) housed in said assembly group (9) by means of a sealing element (8); in particular, said step of sealing provides to thermal heat a film or a rigid lid on each container (2; 2I; 2II; 2III) housed in said assembly group (9) .