Rigid Packaging With Thermoplastic Skeleton And Paper Filling
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Solution Overview
Problem
Current rigid packaging solutions face challenges in reducing environmental impact while maintaining mechanical properties and keeping manufacturing costs low, particularly in achieving both horizontal and vertical rigidity with minimal material usage.
Innovation Solution
A rigid packaging design comprising a thermoplastic skeleton and a heat-sealed sheet, where the skeleton provides horizontal rigidity and the sheet, primarily made of paper fibers, offers vertical rigidity, allowing for reduced material usage and easy recyclability, manufactured through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If packaging is made entirely of thermoplastic material to ensure rigidity, then mechanical strength is improved, but environmental impact increases and material consumption increases
Solution Approach 1:
The packaging combines thermoplastic material and paper in a composite structure. The thermoplastic skeleton provides mechanical strength and rigidity, while the paper filling reduces material consumption and improves recyclability. This composite approach resolves the contradiction by using each material where it is most effective.
Solution Approach 2:
The packaging is divided into distinct functional zones: a thermoplastic skeleton structure that provides rigidity and shape, and paper filling material that occupies internal volume. This segmentation allows each material to be optimized for its specific function, reducing overall environmental impact while maintaining strength.
2Strength
If packaging uses more material to ensure rigidity, then mechanical properties are improved, but manufacturing cost increases
Solution Approach 1:
By using a thermoplastic skeleton with paper filling, the design achieves required rigidity with less total material than solid thermoplastic construction would require. The skeleton provides structural support while the filling material is less expensive and requires less volume.
Solution Approach 2:
Thermoplastic material is applied locally only where structural strength is needed (the skeleton framework), while paper filling is used in regions where rigidity requirements are lower. This localized material distribution optimizes both mechanical properties and material consumption.
3Object-affected harmful factors
If packaging uses complex multi-material structure to reduce environmental impact, then recyclability is improved, but manufacturing complexity increases
Solution Approach 1:
The packaging is manufactured as segmented components (skeleton and filling) that are assembled together. This segmentation enables separate recycling streams for thermoplastic and paper materials while using a simplified injection molding process for the skeleton that integrates the attachment points for paper material.
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 a lightweight, rigid packaging that minimizes material consumption, enhances recyclability, and simplifies manufacturing, thereby reducing environmental impact while maintaining efficiency in processing and distribution.
Implementation Method 1
a first thermoplastic material which has been injected, in a molten state, into a mold
Implementation Method 2
the mold is then cooled and the shell is removed from the mold
Implementation Method 3
The inner layer is heat sealed to the skeleton and the outer layer
Data Source
Figure 1~3
AI summary
Disclosed is a rigid packaging comprising: - a skeleton (30) made of thermoplastic material, this skeleton comprising strands (42) which form meshes of a grid which defines the framework of a side wall (16) of the packaging, - a sheet (32) comprising: • an inner layer made of thermoplastic material, heat welded on the strands (42) of the skeleton, • a cardboard layer, the mass of which represents more than 50% of the total mass of the sheet, - the heat-welded sheet comprising a gripping appendage (62) for the hand of a human being, this appendage being rigidly attached to the cardboard layer and enabling, by manually pulling on this appendage, the manual peeling of the cardboard layer in order to mechanically detach it from the inner layer.