Thermoformed Tray With Support Cut Gaps
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Solution Overview
Problem
Existing packaging methods using plant or cellulosic materials as the base for trays are limited by their lack of expandability, resulting in shallow cavities unsuitable for deep products, and require preformed trays or excessive material, which increases costs and environmental impact.
Innovation Solution
A method involving a base film of plant or cellulosic origin with a support cut to create gaps, bonded with a plastic film to form a deeper tray cavity, allowing for larger packaging areas without increasing base film usage, using a thermoforming machine to apply pressure and heat for bonding and shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If plant or cellulosic materials are used as the base for trays, then environmental friendliness and reduction of plastic usage are improved, but the lack of expandability results in shallow cavities unsuitable for deep products
Solution Approach 1:
The base film is divided into separate regions by support cuts, allowing the plastic film to be drawn over gaps and create deeper cavities while maintaining the eco-friendly plant or cellulosic base material
Solution Approach 2:
The invention combines plant or cellulosic base film with plastic film to create a composite structure that leverages the environmental benefits of the base material while using the plastic's drawability to achieve deep cavity formation
2Shape
If preformed trays or excessive base film are used to achieve deeper cavities, then cavity depth is improved, but manufacturing costs and environmental impact increase
Solution Approach 1:
By introducing support cuts that divide the base film into regions, the invention allows the plastic film to be drawn over gaps, creating deep cavities without requiring excessive base film material or preformed trays
Solution Approach 2:
The invention changes the physical state and configuration of the base film by introducing support cuts, enabling the plastic film to be drawn over gaps and form deeper cavities while using less base film material
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 method enables the creation of deeper packages with reduced base film material usage, maintaining rigidity and stability, while allowing for continuous film supply and increased productivity, and can be used with monolayer plastic films for economic and environmental benefits.
Implementation Method 1
using a thermoforming machine to apply pressure and heat for bonding and shaping
Implementation Method 2
applying a given pressure on a forming area of said films
Implementation Method 3
bonding a plastic film on a base film
Implementation Method 4
said cavity being generated by applying a given pressure on a forming area of said films
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
The invention relates to a method and machine for packaging products, whereby a tray is generated by means of bonding a plastic film to a base film (1), the tray comprising a cavity of a given area and a rim surrounding the cavity. The cavity is generated by applying a given pressure on a forming area (1.0) of said films (1). Before generating the tray and before pressing the base film (1), a support cut (1.2) is generated in the forming area (1.0) of the base film (1), such that with the subsequent pressure on the base film (1) by the support cut (1.2), the base film (1) having at least one gap in the cavity of the tray as a result.