Formed Paperboard Package With Viewing Windows and Upright Stability
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Solution Overview
Problem
Existing product packaging, primarily made from one-time use plastic, poses environmental pollution issues due to slow decomposition and low recycling rates, while paperboard packaging is difficult to shape and lacks transparency.
Innovation Solution
A formed paperboard package comprising a tray and tray cover, with creases to facilitate shaping and a self-support structure for upright stability, featuring windows for product visibility and a heat-sealable design for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one-time use plastic is used for packaging, then ease of manufacture and versatility are improved, but environmental pollution worsens due to slow decomposition and low recycling rates
Solution Approach 1:
The patent changes the material parameter from conventional plastic to molded pulp, fundamentally altering the environmental degradation characteristics while maintaining manufacturability. Molded pulp decomposes rapidly (within weeks to months) compared to plastic's centuries-long persistence, resolving the environmental pollution issue while preserving ease of manufacture through established molding processes
Solution Approach 2:
The patent employs composite material construction by combining molded pulp with clear film windows and adhesive elements. This composite approach allows the primary packaging material (molded pulp) to provide environmental benefits through rapid decomposition, while the clear film and adhesive components enable product visibility and secure closure, thus addressing both environmental concerns and functional requirements
2Object-generated harmful factors
If paperboard packaging is used, then environmental friendliness and recyclability are improved, but difficulty in forming desired shapes worsens
Solution Approach 1:
The patent applies preliminary action by pre-creasing the paperboard blank before final molding. These pre-applied creases create predetermined fold lines that guide the paperboard into the desired three-dimensional shape during the molding process, significantly reducing forming difficulty while maintaining environmental friendliness of the paperboard material
Solution Approach 2:
The patent changes the physical state parameter of paperboard by applying moisture or heat during the molding process. This temporary parameter change increases the plasticity of the paperboard, allowing it to be formed into complex desired shapes more easily, while the material retains its inherent environmental benefits and recyclability
3Object-generated harmful factors
If paperboard packaging is used, then recyclability is improved, but transparency is lost making products difficult to view
Solution Approach 1:
The patent applies segmentation by dividing the packaging structure into distinct functional zones: opaque molded pulp sections for structural support and recycling benefits, and transparent clear film window sections for product visibility. This segmentation allows each material to perform its optimal function - paperboard maintains recyclability while clear film provides transparency, and the two are integrated into a unified packaging system
Solution Approach 2:
The patent uses composite material construction combining molded pulp with clear film windows. The clear film portions are integrated into the paperboard structure, creating a hybrid packaging solution where the paperboard base provides recyclability and the clear film inserts provide transparency for product viewing, thus resolving the contradiction between these two properties
4Object-generated harmful factors
If molded pulp is used, then environmental decomposition is improved, but structural stability in upright orientation worsens
Solution Approach 1:
The patent applies preliminary action by pre-creasing the molded pulp blank to create reinforced structural elements before final assembly. These pre-formed creases and folds create internal support structures that enhance the overall structural stability of the package, enabling it to maintain upright orientation without external support while the molded pulp material continues to decompose rapidly at its natural rate
5Ease of manufacture
If creases are added to paperboard blank, then ease of forming is improved, but risk of tearing during pressing worsens
Solution Approach 1:
The patent applies preliminary action by pre-creasing the paperboard blank in controlled locations before molding. These pre-defined creases concentrate the deformation in specific areas with adequate material thickness and reinforcement, allowing the paperboard to fold cleanly into the desired shape without unpredictable tearing that would occur with spontaneous folding during pressing
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 package is environmentally friendly, easy to recycle, stable in an upright orientation without external support, and allows product visibility, reducing material waste and costs.
Implementation Method 1
The tray may be a formed paperboard tray formed from a paperboard blank having one or more creases. The creases may be configured to aid in forming the paperboard blank into the formed paperboard tray without tearing or destroying the paperboard blank when pressed in a press.
Implementation Method 2
a heat-sealable design for assembly
Data Source
AI summary
A packaging comprises a tray and a tray cover. The tray is formed to define a pocket configured to receive one or more products therein. The tray cover is coupled to the tray over the one or more products in the pocket to close an opening to the pocket. Methods of making the same are further provided.