Snap-Fit Egg Tray Structure for Recyclable Low-Material Packaging

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Solution Overview

Problem

Traditional egg cartons made of materials like expanded polystyrene (EPS) are not biodegradable and pose environmental concerns, and their recycling is often not accepted, while alternative materials like molded pulp or plastic may not be economically viable or sustainable.

Innovation Solution

A two-piece egg tray design comprising a base and a lid, where the base is made from recyclable plastics such as PETE or compostable materials like PLA, and the lid from recyclable paper, allowing for easy assembly and disassembly, reducing material usage and environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If expanded polystyrene (EPS) is used for egg cartons, then cost is reduced, but environmental biodegradability deteriorates and recycling acceptance worsens

Engineering Contradiction:

Improvemanufacturing costVSAvoidenvironmental harm

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from EPS to recyclable plastics (PETE, PP) and compostable materials (PLA, PHA), transforming the environmental properties while maintaining manufacturing feasibility through thermoforming processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material strategies by combining recyclable plastics and compostable materials in the base and lid structures, creating an environmentally friendly composite solution that addresses both cost and environmental concerns

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If traditional EPS cartons are used, then manufacturing is inexpensive, but recycling acceptance deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidrecycling acceptance

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent changes the material composition parameter to use specifically recyclable plastics and compostable materials, which directly improves recycling acceptance while maintaining cost-effectiveness through efficient thermoforming manufacturing

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If alternative materials like molded pulp or plastic are used, then environmental friendliness improves, but manufacturing economy deteriorates

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidmanufacturing economy

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent optimizes material selection by choosing specific recyclable plastics and compostable materials that balance environmental benefits with manufacturing economy, using thermoforming processes that remain cost-effective

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent divides the egg carton into separate base and lid portions that can be manufactured independently and assembled, improving manufacturing efficiency and economy while using environmentally friendly materials

Inventive Principle:

Principle #1Segmentation

4Loss of substance

If a two-piece base and lid design is used, then material usage is reduced, but device complexity increases

Engineering Contradiction:

Improvematerial usageVSAvoidstructural complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent segments the egg carton into a base portion and a lid portion that can be manufactured separately and assembled together, reducing overall material usage while the modular design actually simplifies manufacturing processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines the base and lid into a single functional unit through snapping engagement, creating an integrated egg tray that protects eggs effectively while using less material than traditional one-piece cartons

Inventive Principle:

Principle #5Merging (Combining)

5Ease of operation

If a snapping engagement mechanism is used for lid and base, then ease of operation improves, but device complexity increases

Engineering Contradiction:

Improvelid assembly and disassemblyVSAvoidengagement mechanism complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The snapping engagement mechanism is designed to be self-aligning and self-latching, requiring no additional fasteners or complex assembly steps. The user simply snaps the lid onto the base, and the engagement features automatically secure it in place

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The lid and base are segmented into separate components with dedicated engagement features (protrusions and recesses), allowing for easy assembly and disassembly while keeping each component relatively simple in design

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20260015157A1Egg tray

Publication Date: 2026.01.15 CURIO PRODUCTS INC

AI summary

An egg tray includes a base that includes a plurality of cells, a plurality of posts between the plurality of cells, and a rim extending around an upper perimeter of the base. The egg tray further includes a lid configured to be releasably engaged on the base by snapping the lid onto the base, so that the lid is snapped onto at least one of the plurality of posts and under the rim of the base.