Vacuum Skin Packaging Tray Venting to Eliminate Residual Air Pockets
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Solution Overview
Problem
Existing vacuum skin packaging processes generate residual air pockets and waste due to the need for excess film and inability to remove air after the film contacts the support, which affects shelf-life and package appearance.
Innovation Solution
A vacuum skin packaging process using a tray with at least one hole in the side wall, where air is evacuated through the hole after the film contacts the tray, allowing the film to conform to the product and weld to the inner tray surface, eliminating the need for excess film and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excess film is fed to the vacuum chamber to allow air removal during packaging, then air can be evacuated from the tray, but up to 40% of the film is wasted as scrap
Solution Approach 1:
Air evacuation channels are pre-formed in the tray structure before packaging, allowing air to be removed through designated paths without requiring excess film to create temporary evacuation routes. The channels are created by forming recesses in the tray bottom that extend toward the rim, establishing permanent air egress paths.
Solution Approach 2:
The air evacuation function is extracted from the film and transferred to the tray structure itself. Instead of using excess film to create evacuation pathways, the tray is designed with integrated air evacuation channels that perform this function independently, eliminating the need for film waste.
2Reliability
If the film is held above the support by gripping chains or clamps to allow air removal, then air evacuation is possible, but the device complexity increases
Solution Approach 1:
The tray structure provides its own air evacuation capability through integrated channels, eliminating the need for external holding mechanisms like gripping chains or clamps. The recesses in the tray bottom create self-contained air egress paths that work automatically during the vacuum packaging process.
Solution Approach 2:
The air evacuation function is extracted from the packaging mechanism and transferred to the tray structure. The tray itself becomes the air removal system through its designed recesses, removing the need for complex external holding and evacuation devices.
3Manufacturing precision
If vacuum is applied to pull the film down onto the product, then the film conforms to the product shape, but residual air pockets remain trapped between the film and tray bottom
Solution Approach 1:
Air evacuation channels are pre-formed in the tray structure before packaging, allowing air to be removed through designated paths without requiring excess film to create temporary evacuation routes. The channels are created by forming recesses in the tray bottom that extend toward the rim, establishing permanent air egress paths.
Solution Approach 2:
Instead of trying to push air out from under the film after it contacts the tray, the design inverts the approach by providing dedicated air evacuation channels that actively guide air away during the vacuum process. The recesses create upward air flow paths that prevent pocket formation.
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 process effectively removes air from the tray, minimizing residual pockets and waste, resulting in improved shelf-life and package quality without generating excess film scrap.
Implementation Method 1
a length of a film, typically pre-heated in a separate pre-heating station, is positioned above the article placed on the support. Then the film is drawn upward against a heated dome, so that it is fully heated while held by suction in contact with the heated ceiling and walls of the dome
Implementation Method 2
vacuum is applied to the chamber below the film and all around the supported article. As soon as the pressure in the chamber has reached a suitable level below atmospheric pressure, the suction applied to the dome is released and the softened film is pulled downwards to drape over the contours of the article and in contact with the support
Implementation Method 3
The heated film thus forms a tight skin all around the product and it is welded to the support by differential air pressure, thus forming a seal wherever the two surfaces contact each other
Data Source
AI summary
A vacuum skin package includes a tray and a product loaded on an inner surface of the tray. The tray includes a circumferential side wall upwardly extending from the bottom wall. The side wall defines at least one hole. A film is draped over the product and welded to the inner surface of the tray not occupied by the product to form a skin over the product and the inner surface of the tray and to hermetically close the at least one hole in the side wall of the tray.