Polygonal Thermoplastic Container Assembly for Thin-Wall Stiffness
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Solution Overview
Problem
There is a need to produce thermoplastic containers for foodstuffs and beverages with even smaller wall thickness and lower mass, while maintaining high stiffness, precise geometrical shape, and being composed of a single recyclable material.
Innovation Solution
An intermediate article is formed with a polygonal base and hingedly connected wall elements, using a flexible sheet to create a container with a lattice structure, where each wall element is connected by a fixing mechanism and hinge, allowing for assembly into a polygonal sidewall with a central concavity, and a lid that is removably attached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If wall thickness is reduced to lower mass, then mass is decreased, but structural strength and stiffness deteriorate
Solution Approach 1:
The container wall is segmented into multiple discrete wall elements that can be assembled together, allowing each element to be thinner while the collective structure maintains overall strength through the interlocking arrangement and fixing mechanisms
Solution Approach 2:
The container combines thermoplastic polymer wall elements with a flexible sheet material to create a composite structure that achieves both lightweight properties and structural integrity through the synergistic combination of different materials
2Weight of stationary object
If wall thickness is reduced to lower mass, then mass is decreased, but manufacturing precision and geometrical shape deteriorate
Solution Approach 1:
The container is divided into discrete wall elements that can be precisely manufactured and assembled, allowing for better control of geometrical accuracy in each component while reducing overall material usage
Solution Approach 2:
The wall elements are pre-formed with precise geometries and fixing mechanisms before assembly, ensuring that the final container achieves the required precision through careful preparation and positioning of individual components
3Adaptability or versatility
If single recyclable material is used, then recyclability is improved, but structural complexity increases
Solution Approach 1:
The container uses a composite structure combining thermoplastic polymer wall elements with a flexible sheet, both of which can be made from the same recyclable material, allowing the entire structure to be recycled together while maintaining structural integrity
Solution Approach 2:
The segmented design with discrete wall elements and fixing mechanisms allows for easier disassembly and recycling, reducing the complexity of the recycling process while maintaining structural integrity during use
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 achieves containers with reduced wall thickness and mass, high stiffness, and recyclability, while maintaining structural integrity and functionality.
Implementation Method 1
a flexible sheet which comprises a central part which is bonded to the base wall structure and a plurality of extending parts, each extending part being connected to, and extending away from, the central part, each extending part being bonded to the sidewall structure of a respective wall element
Implementation Method 2
each extending part is connected to the central part by a respective hinge part of the flexible sheet, whereby each wall element is hingedly connected to the base by the respective hinge part, wherein the wall elements can be hinged upwardly relative to the base
Implementation Method 3
each outwardly extending edge comprising at least one member of a respective fixing mechanism for affixing adjacent outwardly extending edges of adjacent wall elements
Implementation Method 4
the sidewall and the base are composed of an injection moulded thermoplastic polymer
Data Source
AI summary
An intermediate article for assembly to form a container, the intermediate article having a base which is polygonal in plan and having an annular peripheral edge with a plurality of edge portions surrounding a base wall structure, a plurality of wall elements around the base, each wall element being adjacent to a respective edge portion of the polygonal base, wherein each wall element has a pair of opposite outwardly extending edges having a sidewall structure therebetween, each outwardly extending edge comprising at least one member of a respective fixing mechanism for affixing adjacent outwardly extending edges of adjacent wall elements, wherein the sidewall and the base are composed of an injection moulded thermoplastic polymer, and a flexible sheet having a central part which is bonded to the base wall structure and a plurality of extending parts, each extending part being connected to, and extending away from, the central part, each extending part being bonded to the sidewall structure of a respective wall element, wherein each extending part is connected to the central part by a respective hinge part of the flexible sheet, whereby each wall element is hingedly connected to the base by the respective hinge part, wherein the wall elements can be hinged upwardly relative to the base to form a container having a sidewall which is polygonal in plan and defines a central concavity for packaging a product, wherein the sidewall has the plurality of wall elements which are connected in series to form an endless wall member extending upwardly from the base, each outwardly extending edge being affixed to an adjacent outwardly extending edge of an adjacent wall element by a respective fixing mechanism at a respective corner portion of the sidewall.