Segmented Deep-Drawn Cardboard Container for Gas-Tight Sealing
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Solution Overview
Problem
Existing deep-drawn cardboard food packaging containers face challenges in achieving a wrinkle-free, continuous edge flange for gas-tight sealing, especially with larger depths, often requiring additional plastic components that increase waste and manufacturing complexity.
Innovation Solution
Divide the container vertically into a deep-drawn base section and a flange section, ensuring a gas-tight connection in an overlapping area to maintain favorable deep-drawing conditions for producing flat, wrinkle-free edge flanges, thereby allowing secure lid sealing without additional plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the container is deep-drawn as a single piece, then the container depth can be increased, but the edge flange becomes wrinkled and unsuitable for sealing
Solution Approach 1:
The container is divided into two separately deep-drawn sections: a base section and an upper section with edge flange. Each section is deep-drawn to a shallower depth, allowing the edge flange to remain flat and wrinkle-free while still achieving the required total container depth when sections are joined.
2Reliability
If plastic injection is used to create the edge flange, then sealing conditions are improved and the container is stiffened, but plastic content increases and manufacturing costs rise
Solution Approach 1:
The entire container including the edge flange is made from cardboard material only, eliminating plastic components. The edge flange is formed through deep-drawing of the cardboard blank itself, maintaining material homogeneity while achieving the required sealing function.
3Ease of manufacture
If the container is deep-drawn with high plastic content, then manufacturing complexity is reduced, but the container becomes hazardous waste
Solution Approach 1:
The container is manufactured as a homogeneous cardboard structure without plastic components. The deep-drawing process is adapted to draw the container in sections and join them, maintaining ease of manufacture while eliminating hazardous plastic waste.
4Quantity of substance
If the edge flange is made from deeply drawn cardboard, then plastic content is reduced, but the flange surface becomes wrinkled and sealing becomes difficult
Solution Approach 1:
The container is segmented into base and upper sections, with the edge flange forming part of the upper section that is separately deep-drawn to a lesser depth. This segmentation allows the flange to maintain surface continuity without wrinkles while still being made entirely of cardboard.
Data Source
Figure 1
Figure 2
AI summary
A food packaging consisting of a deep-drawn, gas-tight sealed cardboard container with a circumferential rim flange (6) projecting from the container shell and a lid (10) sealed to the rim flange (6) is described. To create advantageous manufacturing conditions, it is proposed that the container be divided vertically into a lower bottom section (1) deep-drawn with the base (3) and an upper flange section (2) deep-drawn with the rim flange (6), and that the bottom section (1) and the flange section (2) are gas-tightly connected to each other in an overlap area of the shell parts (4, 5) of the bottom and flange sections (1, 2) spaced apart from the rim flange (6).