Thermoforming Packaging with Segmented Printed Label
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Solution Overview
Problem
Thermoformed film packaging is difficult to recycle due to the use of multiple materials and the presence of printing ink, which prevents the formation of transparent recyclates, making it largely disposable and contributing to plastic waste.
Innovation Solution
A thermoforming film packaging design where a printed material section is attached to the packaging body via a fastening seam that covers only a small portion of the edge, allowing for easy removal and recycling, with the option for the fastening seam to be either heat-sealable or adhesive, and the packaging body to be made from the same material type to facilitate material recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple materials and printing ink are used in thermoformed film packaging, then visual appeal and information visibility are improved, but recyclability deteriorates
Solution Approach 1:
The packaging is divided into a packaging body and a separate printed material section. The printed material section is attached via a fastening seam that allows easy separation, enabling the packaging body to be recycled independently while the printed section can be removed and disposed of separately, thus resolving the contradiction between visual appeal and recyclability
Solution Approach 2:
The printed material section is extracted as a separate component from the packaging body. By attaching it only at part of the peripheral edge through a removable fastening seam, the printing ink and additional material are separated from the recyclable packaging body, allowing the body to be recycled without contamination from ink and multi-material composites
2Loss of information
If a printed material section is attached to the packaging body, then information visibility is improved, but manufacturing complexity increases
Solution Approach 1:
The information-bearing printed material section is segmented as a separate component rather than being integrated into the packaging body. This segmentation allows for simplified manufacturing of the packaging body itself, while the printed section can be produced separately and attached later, reducing overall manufacturing complexity
Solution Approach 2:
The printed material section is prepared in advance as a separate component with pre-applied printing and pre-attached fastening features. This preliminary preparation allows the packaging body to be manufactured independently and then assembled with the pre-prepared printed section, streamlining the overall manufacturing process
3Ease of operation
If the fastening seam covers only a small portion of the edge, then ease of removal is improved, but sealing reliability deteriorates
Solution Approach 1:
The fastening seam is segmented to cover only specific portions of the peripheral edge rather than the entire edge. This selective segmentation provides sufficient attachment for normal handling while leaving other portions free for easy grasping and removal, balancing sealing reliability with ease of opening
Solution Approach 2:
The fastening seam is applied with local quality variation - providing strong attachment at specific locations where sealing is needed, while deliberately leaving other locations with minimal or no attachment to facilitate easy grasping and removal by the end user
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 enhances recyclability by allowing the packaging body to be recycled easily and reduces material waste, while maintaining visual appeal and information visibility through strategic placement of printed information.
Implementation Method 1
Heat-sealed or adhesive seams
Implementation Method 2
Heat-sealed or adhesive seams
Data Source
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AI summary
This is a thermoformed film packaging with a packaging body (1) consisting of a tray (2) and a cover film (3), wherein the cover film (3) closes the tray (2) and the tray (2) is formed from a thermoformed film. According to the invention, a printed material section (6) is arranged on the packaging body and is attached to the packaging body (1) only in part of a circumferential edge by a fastening seam (7).