Tray Flange Hinge Design Prevents Overwrap Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hard plastic trays are prone to cutting through overwrapping during or after overwrapping, leading to oxygen leakage and spoilage of food items.
Innovation Solution
A tray design featuring a flange with hinges that can be folded downward, positioning the trim edge away from the overwrap to prevent cutting, made from materials like polyethylene terephthalate (PET) or other durable plastics, ensuring the overwrap remains intact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard plastic trays are used, then structural strength is improved, but the edges cut through the overwrapping causing leakage
Solution Approach 1:
The tray edge is segmented into multiple components: a vertical wall portion and a horizontal flange portion. This segmentation allows the flange to extend outward and protect the overwrap from the sharp trim edge, while the wall provides structural strength. The flange acts as a separate protective element that prevents the trim edge from contacting and cutting the overwrap.
Solution Approach 2:
The flange serves as an intermediary element between the tray wall and the overwrap. It positioned the trim edge away from the overwrap by extending outward, so that the flange physically separates the sharp trim edge from the overwrap material, preventing direct contact and cutting while maintaining structural integrity.
2Strength
If foamed plastic is used, then cushioning properties are improved, but environmental sustainability deteriorates
Solution Approach 1:
The material parameter is changed from foamed plastic to hard plastic with a specific flange geometry. This parameter change allows the use of environmentally friendly hard plastic materials while compensating for the loss of cushioning properties through the engineered flange structure that provides both protection and cushioning functionality.
3Object-affected harmful factors
If the flange is folded downward, then overwrap protection is improved, but manufacturing complexity increases
Solution Approach 1:
The flange is pre-formed with a hinge line during the molding process, creating a predetermined folding line. This preliminary action allows the flange to be easily folded downward during packaging or assembly without requiring complex manufacturing equipment. The hinge line is created as part of the initial molding, simplifying the subsequent folding operation.
Solution Approach 2:
The flange is designed with hinge lines that allow it to be dynamic - it can be folded downward to protect the overwrap during packaging or storage, and potentially unfolded or adjusted during use. This dynamic capability provides overwrap protection when needed without permanently complicating the tray structure.
Data Source
AI summary
A tray comprising: a base having a base perimeter and a wall extending upward from the base perimeter. The wall is continuous around the base perimeter. The wall includes an inner wall surface and an outer wall surface. The wall includes a first end at the base perimeter and a second end opposite the first end. The tray also includes a flange extending outward from the second end of the wall. The flange includes one or more hinges, a top flange surface, a bottom flange surface, and a trim edge. The flange and the one or more hinges extend continuously around the second end of the wall. At least a portion of the flange is configured to be folded downward such that at least a portion of the bottom flange surface is closer to the outer wall surface after being folded.