Thermoformed Packaging Pigment Embedding
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Solution Overview
Problem
Current methods for decorating and pigmentation of rigid thermoformed packaging units suffer from inconsistency, distortion, and cost due to surface printing or pigmenting, which leads to poor appearance and susceptibility to damage.
Innovation Solution
Thermoformable sheets with a multilayer film and printed pigment deposit located between two thick rigid components, allowing for improved thermoformability and protection of the pigment, reducing distortion and fading, and enhancing the appearance and cost-effectiveness of the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If graphics are printed directly on the exterior surface of a rigid thermoformable sheet before thermoforming, then the printing process can be simplified, but the graphics become distorted and fade due to stretching during forming
Solution Approach 1:
The invention embeds the printed graphic within the thickness of the thermoformable sheet (moving from 2D surface to 3D volume), allowing the graphic to be protected by surrounding material during thermoforming. The print is applied to a thin web that becomes sandwiched between thick rigid components, creating a layered structure where the graphic resides in the interior rather than on the exterior surface.
Solution Approach 2:
The invention creates a composite structure combining a printed thin web with thick rigid components (such as foam or plastic layers). This composite construction protects the printed graphic during thermoforming while maintaining the structural integrity of the final packaging unit. The different materials serve complementary functions: the thin web provides the graphic, while the rigid components provide structural support and protection.
2Reliability
If a multilayer thermoformable film with internal printed image is produced, then graphic protection is improved, but the printing becomes non-uniform in deep draw applications
Solution Approach 1:
The invention applies printing to a specific localized region (the thin web) rather than attempting to print on the entire thick sheet. This thin web is then positioned between thick rigid components, creating a structure where the graphic is locally protected. The printing process only needs to handle the thin web, which maintains dimensional stability during printing, ensuring uniformity.
3Adaptability or versatility
If ink is printed on the exterior surface of a formed part, then decoration can be added after forming, but the ink is susceptible to abuse and requires protective overlacquer
Solution Approach 1:
The printing is performed on the thin web before the web is assembled into the final packaging structure. This preliminary printing action allows the graphic to be applied to a flat, stable surface where printing conditions can be optimized. The printed web is then sandwiched between rigid components that protect the graphic during subsequent thermoforming and handling, eliminating the need for additional protective coatings.
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 solution results in thermoformed packaging units with less pigment thinning and distortion, improved appearance, and reduced costs compared to traditional methods, especially evident in deep draw applications with a draw ratio greater than 4.
Implementation Method 1
thermoformable sheets that can be thermoformed into packaging components such as trays or cups
Implementation Method 2
The pigment deposit is subsequently located between two relatively thick rigid components to form the thermoformable sheets
Data Source
AI summary
A thermoformed packaging unit is produced from a thermoformable sheet that has a printed pigment deposit located generally in a central position between the first and second rigid components. The packaging unit has only a low level of pigment distortion even when thermoformed to a draw ratio greater than 4.