Monolithic Cardboard Tray With Continuous Rim for Gap-Free Sealing
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Solution Overview
Problem
Existing methods for producing trays from cardboard or corrugated board blanks result in significant waste and inefficiencies due to the use of multiple components, which complicates recycling and increases environmental impact and production costs.
Innovation Solution
A monolithic blank with specific flap configurations and folding methods, allowing a single blank to form a tray with a continuous, stiff rim, which can be sealed without gaps and efficiently stacked, using a dedicated apparatus for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (cardboard blank and plastic film) are used to form the bowl, then the structural integrity and functionality are achieved, but the recycling complexity increases and environmental impact worsens
Solution Approach 1:
The invention merges the cardboard tray and plastic sealing film into a single integrated structure where the plastic film is attached directly to the folded cardboard flaps, creating a unified component that maintains structural integrity while simplifying recycling by enabling easy separation of the two materials after use
2Ease of manufacture
If multiple separate blanks are used to produce the tray, then the tray structure can be formed, but the material waste increases and production costs rise
Solution Approach 1:
The invention segments a single large cardboard blank into functional components (base panel, side walls, and flaps) through folding lines and detachment lines, allowing the entire tray structure to be formed from one blank without material waste from joining multiple pieces
3Reliability
If a continuous rim is formed from a single blank, then sealing efficiency improves and gaps are eliminated, but the blank design complexity increases
Solution Approach 1:
The invention incorporates pre-perforated detachment lines and pre-formed flap structures in the blank design that enable the continuous rim to be automatically formed during the folding and assembly process, eliminating the need for post-assembly sealing operations while maintaining manageable blank design
4Productivity
If high-speed sealing procedures are used, then production productivity increases, but the rim stiffness must be sufficiently high to support the sealing process
Solution Approach 1:
The invention forms the rim with a doubled thickness through the folding of flaps over the edge, creating a curved, reinforced structure that provides the necessary stiffness to support high-speed sealing operations while maintaining structural integrity during the sealing process
Data Source
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AI summary
The bowl includes a tray (50) obtainable from a monolithic blank comprising a main panel (10) having a perimeter formed by a plurality of sides (12, 14, 16), wherein each side is provided of a respective flap (18) consisting of an internal tab (20), a median panel (22) and an external sub-flap (24). A bottom panel (38) is defined within the main panel (10) by folding perimetric lines (40) parallel to said sides, respectively, of the main panel (10). Respective wings (42) join at least some of said perimetric lines (40) to a respective end part of the main panel (10) which is adjacent to one of said sides, said end parts collectively forming a continuous rim (46) completely surrounding said bottom panel (38).