Injection Molded Tray with Snap-Connect Cover Rim
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Solution Overview
Problem
Existing packaging methods require user intervention to break the seal and may involve additional steps, such as placing the cover rim on the tray before applying the cover foil, which can lead to inefficiencies and material waste.
Innovation Solution
A method involving injection moulding to create a plastic tray and cover rim connected by a thin film, where the film is broken during manufacturing, allowing for a snap connection and simultaneous application of cover foil to the cover rim, ensuring a reliable seal without user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover rim is placed on the tray before applying the cover foil, then the sealing process can be completed, but an additional manufacturing step is required which reduces productivity
Solution Approach 1:
The patent combines the cover rim and tray into a single integrated component formed by injection molding. The cover rim is directly molded as part of the tray structure, eliminating the need for separate placement steps. This merging of components maintains sealing reliability while significantly improving manufacturing productivity by reducing the number of assembly operations required.
Solution Approach 2:
The cover rim is pre-formed as an integral part of the tray during the injection molding process itself, before the cover foil application step. This preliminary integration ensures the cover rim is already in its correct position and orientation, eliminating the need for subsequent manual or automated placement operations and streamlining the overall manufacturing process.
2Reliability
If a separate cover foil is used for sealing, then the tray can be sealed reliably, but the cover foil becomes waste after first use and additional material is consumed
Solution Approach 1:
The invention merges the cover rim and tray into a single durable component that remains on the tray permanently. The integrated structure eliminates the need for separate cover foils that would be discarded after one use. Material is saved because the combined component can be reused multiple times, and only the minimal necessary sealing material is consumed each time.
Solution Approach 2:
The patent eliminates the discard cycle by making the cover rim an permanent part of the tray. Instead of using disposable cover foils that are discarded after one use, the integrated cover rim is recovered and reused with each subsequent sealing operation, significantly reducing material waste and loss of substance.
3Ease of operation
If the thin film connecting the cover rim to the tray is broken by user intervention, then the cover can be opened, but user intervention is required which reduces ease of operation
Solution Approach 1:
The thin film is pre-positioned and pre-stressed during the injection molding process to create a built-in breaking mechanism. The film is arranged so that normal opening actions automatically break it without requiring user intervention or special tools. This preliminary configuration enables automatic opening functionality while maintaining ease of operation.
Solution Approach 2:
The cover rim structure is designed to be self-opening through the automatic breaking of the thin film connection. When the cover is lifted, the film breaks on its own without requiring user action, enabling the system to service itself. This self-service mechanism improves ease of operation while maintaining automatic sealing functionality.
Data Source
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AI summary
For the purpose of manufacturing a package, an entirety is provided by means of injection moulding, the entirety including a plastic tray (10) having an open side and a ring-shaped plastic cover rim (20) which is located at the open side of the tray (10), at a circumferential rim of the tray (10), and which surrounds that circumferential rim. The cover rim (20) is connected to the tray (10) by means of a relatively thin plastic film, wherein the cover rim (20) and the tray (10) are detached from each other by forcing a limited mutual movement of the cover rim (20) and the tray (10). Furthermore, a piece of cover foil (40) is provided and connected to at least the cover rim (20). Preferably, the cover rim (20) and the tray (10) are adapted to be capable of getting into engagement with each other by means of a snap connection after they do no longer form an integral entirety with each other.