Notched Hinge Connection in Thermoformed Containers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermoformed plastic containers with hinge connections face challenges in achieving a strong, consistent, and easily foldable design that minimizes equipment wear and tear, while maintaining multiple opening capabilities.
Innovation Solution
A method and apparatus for forming a notched hinge connection in thermoformed containers by severing along a hinge line with alternating connecting membranes, where the membranes are formed on the outer side or along the hinge axis, using a mold with notches to reduce knife wear and ensure consistent folding, and a clamping mechanism to hold the hinge area during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous hinge line is used to ensure strength, then the hinge can withstand multiple openings, but it becomes difficult to fold mechanically and causes excessive wear on cutting equipment
Solution Approach 1:
The hinge line is segmented into alternating severed portions and connecting membranes, creating a notched hinge connection that allows mechanical folding while maintaining strength through the distributed membrane structures
2Ease of operation
If notches are provided in the cutting knife to form connecting membranes, then the hinge can be folded easily, but the knife experiences rapid wear and degradation requiring frequent replacement
Solution Approach 1:
Instead of providing notches in the cutting knife, the invention inverts the approach by providing notches in the mold surface, allowing the knife to cut continuously while the mold forms the connecting membranes, thereby eliminating knife wear from notch formation
3Strength
If the hinge area is made strong to withstand multiple openings, then durability is improved, but the hinge becomes less flexible and harder to fold
Solution Approach 1:
The hinge structure employs local quality by concentrating membrane connections at specific spaced intervals along the hinge line, providing localized strength where needed while maintaining flexibility in the severed portions, achieving both durability and foldability
Data Source
AI summary
Method and apparatus for forming a hinge in a thermoformed container, such as an egg carton, and the resulting container. The hinge is formed in the mold, by severing a thermoformed container along the length of a hinge line, with the exception of plurality of spaced connecting membranes that are not severed. The alternating severed portions and connecting membranes are referred to herein as a notched hinge connection. The width, depth, and location of the connecting membranes can be adjusted so the hinge area is strong enough to withstand multiple openings during use.