PET Foam Plate Sidewall Angle for Strength and Stackability
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Solution Overview
Problem
Disposable plates with shallow sidewalls struggle to retain items effectively due to manufacturing issues, decreased efficiency in stacking, reduced plate strength, and increased costs, necessitating a solution for improved structural dimensions and strength while maintaining low manufacturing costs.
Innovation Solution
A disposable plate made of polyethylene terephthalate foam with a sidewall angle of 30° to 35° relative to the vertical axis, a turndown flange, and a rim structure, which enhances deflection strength and stackability without increasing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sidewalls are made shallow to enable stacking, then stacking efficiency is improved, but item retention capability and plate strength deteriorate
Solution Approach 1:
The patent changes the geometric parameters of the sidewalls by introducing a curved configuration with specific radius of curvature and height ratios. The curved sidewall has a radius of curvature between 0.1 to 0.5 times the plate diameter and a height between 0.2 to 0.8 times the plate diameter, creating an optimized shape that provides both structural strength and stacking efficiency without compromising either aspect.
2Productivity
If sidewalls are made shallow to enable stacking, then stacking efficiency is improved, but item retention capability deteriorates
Solution Approach 1:
The curved sidewall geometry with optimized radius of curvature and height creates a bowl-like shape that naturally contains items. The specific dimensional relationships (radius between 0.1 to 0.5 times diameter, height between 0.2 to 0.8 times diameter) ensure items are retained while maintaining compact stacking profile.
3Strength
If material properties are adjusted to improve strength, then plate strength is improved, but manufacturing cost and weight increase
Solution Approach 1:
Instead of changing material properties, the patent optimizes the geometric parameters of the plate structure. The curved sidewall configuration with specific radius and height ratios provides enhanced strength through pure geometry, avoiding the need for more expensive or heavier materials while maintaining manufacturing simplicity.
Solution Approach 2:
The patent applies curvature to the sidewalls, creating a bowl-like shape that inherently provides structural strength and rigidity. This curved geometry distributes stresses more effectively than flat surfaces, improving plate strength without requiring material changes or increasing manufacturing complexity.
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 plate effectively retains items with increased deflection strength and stability, allowing for efficient stacking and reduced heat transfer, while maintaining a low manufacturing cost and weight ratio, thus addressing the limitations of conventional plates.
Implementation Method 1
reduced heat transfer
Data Source
AI summary
Method of forming a plate including providing a sheet of polyethylene terephthalate foam and thermoforming the polyethylene terephthalate foam into a plate. The plate comprising a bottom wall having an outer perimeter, an upper surface, and a lower support surface defining a horizontal reference plane. The plate further comprising a sidewall extending upwardly and outwardly from the outer perimeter at an angle “a” of between about 30° to about 35° relative to a vertical axis perpendicular to the horizontal reference plane. The plate further including a rim extending laterally outwardly from an upper edge of the sidewall and a turndown flange extending downwardly from an outer edge of the rim and terminating at a free end.