Thermoformable Plastic Pleated Cup for Confectionery Packaging

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Solution Overview

Problem

Conventional pleated cup containers made from paper materials are limited in output due to sheet thickness constraints and lack an attractive appearance, with pleated walls unable to withstand radial stresses, causing them to return to their original flat state.

Innovation Solution

A cup-shaped container formed from a thermoformable plastics material, specifically polyolefin films like polypropylene, which are shaped using thermoforming to create a pleated lateral wall and a flat base, allowing for increased production while maintaining dimensional tolerance and an attractive appearance similar to aluminum foil containers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pleated cups are made from paper materials and deep drawn to increase output, then production quantity increases, but dimensional tolerance limits are exceeded

Engineering Contradiction:

Improvenumber of cups produced per operationVSAvoiddimensional tolerance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the material parameter from paper to thermoformable plastics, which fundamentally alters the forming behavior. Plastics materials allow for precise control of deformation during thermoforming, enabling high production quantities while maintaining dimensional accuracy through controlled thermal and mechanical parameters.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the purely mechanical deep drawing process with a thermoforming process. This substitution allows for better control of the forming process through thermal energy, enabling simultaneous production of multiple cups while maintaining dimensional tolerance through controlled heating and forming parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If pleated cups are made from paper materials, then production is simple, but the containers lack attractive appearance

Engineering Contradiction:

Improveproduction simplicityVSAvoidappearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent changes the material parameter from paper to thermoformable plastics, which enables superior appearance qualities. The plastics material allows for better surface finish, color variation, and reflective properties while maintaining the pleated structure through controlled forming parameters.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes thermoformable plastics materials that can be engineered with specific surface properties, colors, and finishes to achieve attractive appearances. The material can be selected or treated to provide metallic sheen, matte finishes, or other aesthetic qualities while maintaining the functional pleated structure.

Inventive Principle:

Principle #40Composite materials

3Reliability

If pleated cups are made from paper materials, then they are inexpensive, but the pleated walls cannot withstand radial stresses

Engineering Contradiction:

Improvestructural stabilityVSAvoidradial stress resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the material parameter from paper to thermoformable plastics, which fundamentally improves structural performance. The plastics material provides better mechanical strength and elasticity, allowing the pleated walls to withstand radial stresses from confectionery products without collapsing or deforming.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs thermoformable plastics as flexible thin film material that can be formed into pleated structures. The material maintains flexibility for the pleated appearance while providing sufficient structural integrity to contain products, combining the advantages of flexibility and strength.

Inventive Principle:

Principle #30Flexible shells and thin films

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 use of thermoformable plastics materials enables the production of a large number of stable, attractive cup-shaped containers with pleated walls that do not self-support, suitable for containing confectionery products, by allowing for simultaneous thermoforming of multiple sheets and rapid cooling to retain the cup configuration, overcoming the limitations of paper-based containers.

Implementation Method 1

a cup-shaped container made from sheet material shaped by thermoforming

Methodology Applied

Scientific EffectThermoforming: Heat Treatment

Implementation Method 2

rapid cooling to retain the cup configuration

Methodology Applied

Scientific EffectRapid cooling: Cooling

Implementation Method 3

these stresses cause the pleats to expand so that the sheet forming the container tends to return to its original flat state

Methodology Applied

Scientific EffectElastic recovery: Elasticity

Data Source

PatentEP2082974B1Cup-shaped container and method for confectionery products

Publication Date: 2017.10.25 SOREMARTEC SA(BE)

AI summary

What is described is a cup-shaped container having a base wall (2) and a lateral wall (4) which is at least partially pleated, of the type commonly known as a pleated cup. This container is characterized in that it is formed from a sheet or film of plastics material which is made to be thermoformable, particularly polypropylene or a homopolymer or a copolymer. The container can be produced by a pressing method which comprises hot pressing to form the cup shape and subsequent rapid cooling of the container shaped in this way.