Self-Folding Pizza Box Carrier with Nested Pads
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Solution Overview
Problem
Current packaging solutions for pizza slices, especially those cut into quarters, sixths, or eights, face challenges such as adhesion issues, lack of microbiological safety, high costs due to large surface areas and PET layers, and difficulty in forming and transporting, while also failing to maintain shape during hot food handling.
Innovation Solution
A self-folding pizza box design featuring a carrier formed by superposed pads with locking elements, made from cardboard with an optional aluminized PET film, allowing for easy formation and insertion, maintaining strength during hot handling, and enabling efficient packing and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cardboard boxes are used for packing pizza slices, then the package can be printed and is cost-effective, but the cardboard does not possess sufficient strength to keep its shape during packing of hot slices
Solution Approach 1:
The patent applies composite materials by combining cardboard with PET foam inserts. The cardboard provides printability and cost-effectiveness, while the PET foam inserts provide structural strength and shape retention. The composite structure allows each material to contribute its advantageous properties, resolving the contradiction between ease of manufacture and strength.
Solution Approach 2:
The packaging is segmented into multiple functional components: cardboard outer shell for printing and cost-effectiveness, PET foam inserts for structural support, and separate compartments for individual pizza slices. This segmentation allows each component to optimize its specific function while working together as a unified package.
2Quantity of substance
If the surface area of the box is increased to accommodate multiple slices, then more slices can be packed, but the package becomes difficult to pack into bags and transport
Solution Approach 1:
The packaging design uses nested structures where smaller compartments for individual pizza slices are nested within the larger box structure. The PET foam inserts are nested within the cardboard box, creating a compact hierarchical arrangement that maximizes slice capacity while maintaining a space-efficient external form for easy bagging and transport.
3Reliability
If PET layer is added to cardboard for microbiological safety, then health safety is improved, but the price and space requirements increase dramatically
Solution Approach 1:
Instead of applying PET coating to the entire cardboard surface, the patent uses localized PET foam inserts only in critical areas where microbiological protection is most needed, such as the bottom and sides that contact the pizza. This local application provides necessary protection while minimizing material costs and space requirements.
4Strength
If cardboard thickness is increased to maintain shape, then structural strength is improved, but the package becomes more expensive and less competitive in price
Solution Approach 1:
The patent uses composite materials where thin cardboard is combined with PET foam inserts. The cardboard provides a thin, cost-effective outer shell, while the PET foam inserts provide the necessary structural strength and shape retention. This composite approach avoids the need for thick, expensive cardboard while maintaining adequate strength.
Data Source
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AI summary
A self folding box with a carrier for packing of pizza, as well as a tool for forming the box, comprises a box (A) with a lower part (1) of the box and a cover (2) of the box, wherein on a bottom (1.1) of the lower part (1) of the box is placed a carrier (4) for two slices of pizza quarter. Lateral sides (1.2, 2.2), auxiliary sides (1.8, 2.8) and an opposite side (1.5, 2.5) are made around bottom (1.1, 2.1) both of the lower part (1) and the cover (2) of the box (A). The lateral sides (1.1, 2.1) and the auxiliary sides (1.8, 2.8) are mutually connected and locked by means of tongues (1.3) entering slots (1.10). The opposite side (1.5, 2.5) is locked in a slot (1.7) in the bottom (1.1, 2.1) by means of a tongue (1.6). The carrier (4) comprises two pads (3) for one slice of pizza quarter, which are superposed one on another, so that the tongues (3.3, 3.4, 3.6) of the sides (3.2) of the upped pad (3) enclose from outside the sides (3.2) of the lower pad (3), while the trapezoidal tongues (3.5) of the lower pad (3) enter the openings (3.7) of the upper pad (3). An auxiliary tongue (3.9) of the lower auxiliary carrier (3.8) encloses from outside the upper auxiliary carrier (3.8). The pad (3) for two slices of pizza quarter is formed by manual folding the cardboard formed unfolded blank (F) along the folding lines (3.21, 3.81, 3.91). Forming the box (A), i.e. both the lower part (1) and the cover (2) thereof is carried out in the same tool (9) that comprises a tool holder (9.1), on which is attached a tool bottom (9.2) with the sides (9.3, 9.4, 9.5, 9.6) for forming the box. There is also a variant of the invention defined by the box (A1).