Multilayer Tray with Draining Effect and Recycling
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Solution Overview
Problem
Existing food packaging solutions for products that release fluids, such as meat or fish, are costly to produce, complex to recycle, and lack sustainability due to the use of different materials for trays and absorbent pads, and current alternatives like open-cell draining trays are not environmentally friendly as they cannot be produced from recycled materials.
Innovation Solution
A multilayer tray with a draining effect is created using extruded polyester foam as the base layer and polyester fiber fabric as the absorbent layer, both made from recycled materials, which can be produced using traditional plastic tray machinery and easily recycled, with an optional rigid polyester layer for improved adhesion and a perforated PET film for enhanced sealing and fiber prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate absorbent pads made from different materials are used in combination with trays, then fluid absorption capability is improved, but manufacturing cost increases and recycling complexity increases
Solution Approach 1:
The patent combines the tray and absorbent pad into a single integrated structure where the tray itself incorporates absorbent layers. The tray comprises a base layer, an intermediate layer with capillary channels, and an absorbent layer, eliminating the need for separate absorbent pads and simplifying both manufacturing and recycling processes.
Solution Approach 2:
The patent uses composite material structures within the tray, specifically combining thermoplastic polyurethane (TPU) with other polymers to create layers with different functional properties. The intermediate layer uses TPU's elastic memory effect to create reversible capillary channels, while the absorbent layer uses hydrophilic polymers for fluid absorption, achieving multiple functions within a single recyclable component.
2Reliability
If open-cell draining trays made from expanded polystyrene are used, then fluid absorption is improved, but environmental sustainability deteriorates due to inability to produce from recycled materials
Solution Approach 1:
The patent changes the physical state and structure of thermoplastic polyurethane through temperature-dependent phase transitions. The TPU intermediate layer exhibits elastic memory effect where capillary channels form at elevated temperatures and close at lower temperatures, enabling reversible fluid absorption without requiring expanded polystyrene or other non-recyclable materials.
3Reliability
If multiple separate components (tray, pad, sealing film) are used, then fluid management function is improved, but manufacturing cost increases due to multiple production and assembly operations
Solution Approach 1:
The patent merges the tray structure with multiple functional layers (base layer, intermediate layer with capillary channels, and absorbent layer) into a single molded component. This integration eliminates separate production and assembly operations for trays, pads, and sealing films, reducing manufacturing complexity and cost while maintaining comprehensive fluid management capabilities.
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 multilayer tray effectively contains exuded liquids without the need for internal absorbent pads, simplifies recycling by using the same material for all layers, and reduces manufacturing costs while being environmentally sustainable.
Implementation Method 1
an intermediate layer (15) with capillary channels, between said base layer and said absorbent layer
Implementation Method 2
an absorbent layer (20), in contact with said base layer, able to absorb the exuded liquids
Data Source
Figure 1
AI summary
The present invention concerns a multilayer tray with a draining effect, comprising a base (2), lateral walls (3) and an upper rim (4), wherein said tray is formed out of a multilayer material comprising, in succession from the outside inwards: an outermost layer of extruded polyester foam (XPET) and a layer of fabric made of polyester fiber having an absorbent capacity, optionally covered by a perforated PET film.