Thermoformed Container Assembly with Fibrous Support for Reduced Plastic Use
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Solution Overview
Problem
The rapid growth in the use of thermoformed plastic containers for food packaging contributes to environmental issues due to high plastic material consumption, leading to a significant carbon footprint and marine pollution.
Innovation Solution
A container assembly comprising a thermoformed plastic container with a support and a flexible lid, where the support is attached to the container flange using heat sealing materials, allowing for a single-step assembly and reducing plastic usage by incorporating a fibrous material for the support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermoformed plastic container is used for food packaging, then the container provides effective storage and transportation functionality, but the amount of plastic material used increases, leading to environmental pollution and carbon footprint
Solution Approach 1:
The container system is divided into separate components: a plastic container for food storage, a fibrous support structure for structural integrity, and a flexible lid for sealing. This segmentation allows each component to be optimized for its specific function while reducing overall plastic usage.
Solution Approach 2:
The invention combines different materials (plastic, fibrous materials like paper or cardboard) to create a hybrid container system that maintains the necessary structural properties and functionality while reducing dependence on plastic materials alone.
2Adaptability or versatility
If multiple components (container, support, lid) are assembled separately, then each component can be optimized independently, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The support structure integrates multiple functions: it provides structural reinforcement to the container, serves as an attachment point for the lid, and facilitates sealing. By merging these functions into a single component, the assembly process is simplified while maintaining component optimization.
Solution Approach 2:
The fibrous support acts as an intermediary element between the plastic container and the flexible lid, providing a interface that simplifies the connection process and enables effective sealing without complex assembly steps.
3Productivity
If heat sealing is applied to both upper and lower surfaces of the container flange, then the lid and support are securely attached in a single step, but the heat sealing process becomes more complex
Solution Approach 1:
The sealing approach transitions from a traditional single-side heat sealing process to a dual-side simultaneous sealing process. By applying heat to both the upper and lower surfaces of the flange at the same time, the attachment of both the lid and support is achieved in a single operation, effectively adding a dimensional aspect to the sealing process.
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
This design minimizes plastic material usage while facilitating efficient assembly and recycling, thus mitigating environmental impact and improving manufacturing efficiency.
Implementation Method 1
a flexible container lid attached to an upper surface of the container flange by a first heat sealing material
Implementation Method 2
the support flange is attached to the lower surface of the container flange by a second heat sealing material
Implementation Method 3
heat may be applied to the upper surface of the container flange to heat the upper and lower surfaces of the container flange. Put another way, heat may be applied directly to the upper surface of the container flange and indirectly to the lower surface of the container flange through said container flange
Data Source
AI summary
A container assembly has a thermoformed plastic container with a base and a container wall terminating at a container flange, and a flexible container lid is attached to an upper surface of the container flange by a first heat sealing material The assembly also includes a support with a support wall surrounding the container wall and terminating at a support flange, wherein the support flange is configured and arranged to abut against a lower surface of the container flange, and is attached thereto by a second heat sealing material.