Tray-less Multi-compartment Package Rigid Frame

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Solution Overview

Problem

Conventional multi-compartment packaging systems require a supporting tray for rigidity, leading to increased volume, weight, manufacturing costs, and environmental impact, while also facing issues with cross-contamination, product sticking, and reduced shelf life due to the use of different materials for trays and lids.

Innovation Solution

A tray-less multi-compartment package is developed using crystallizable polymers that form a continuous rigid frame through partial heat-induced crystallization during sealing, eliminating the need for a supplemental tray and allowing for individual compartment opening and reuse.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a supporting tray is used to provide rigidity to multi-compartment packages, then structural stability is improved, but package volume, weight, and manufacturing costs increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidpackage volume

Core Design Contradiction:

Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

The patent merges the functions of the sealing films and the supporting tray into a single integrated structure. The rigid frame is formed directly from the sealing films through heat-induced crystallization, eliminating the need for a separate tray component while maintaining structural stability and reducing package volume.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If a supporting tray is used to provide rigidity to multi-compartment packages, then structural stability is improved, but package weight increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidpackage weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The patent combines the sealing and structural support functions into the same film material. The rigid frame is created through heat-induced crystallization of the sealing films themselves, eliminating the weight of a separate tray while maintaining structural stability.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If different materials are used for trays and lids in multi-compartment packages, then manufacturing flexibility is improved, but manufacturing costs and environmental impact increase

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent uses the same crystallizable polymer material for both the sealing films and the rigid frame structure. This homogenization of materials simplifies manufacturing processes, reduces costs, and improves recyclability while the heat-induced crystallization provides the necessary structural properties.

Inventive Principle:

Principle #33Homogeneity

4Ease of manufacture

If traditional sealing methods are used without heat-induced crystallization, then sealing simplicity is maintained, but structural rigidity and handling capability deteriorate

Engineering Contradiction:

Improvesealing simplicityVSAvoidstructural rigidity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent changes the physical-chemical parameters of the sealing process by applying heat to induce crystallization in the polymer films. This parameter change transforms the films from a flexible, weak state during sealing to a rigid, strong state after cooling, providing both ease of sealing and structural rigidity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes the phase transition of the crystallizable polymer from amorphous to crystalline state through heat-induced crystallization during sealing. This phase transition provides the mechanism for transforming the material properties from soft and formable during sealing to rigid and strong after cooling, resolving the contradiction between sealing simplicity and structural rigidity.

Inventive Principle:

Principle #36Phase transitions

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

The solution reduces material consumption, manufacturing costs, and environmental impact while maintaining product sterility and preventing cross-contamination, with improved handling and storage capabilities.

Implementation Method 1

the crystallizable polymer is at least partially crystallized in correspondence of the sealing area, thus providing a peripheral circumferential continuous rigid frame

Methodology Applied

Scientific EffectHeat-induced crystallization: Crystallisation

Data Source

PatentEP2765092B1Multi-compartment tray-less package with a rigid frame

Publication Date: 2015.09.02 CRYOVAC INC

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Figure 2A~2B
Figure 3A~3B

AI summary

A tray-less multi-compartment plastic flexible package, preferably used for food or medical packaging applications, and methods for its manufacture are described. The present package does not require a supplemental tray being sufficiently rigid as such, thanks to the partial crystallization of crystallizable films along a frame in correspondence of the sealing area. The absence of a tray makes the present packages particularly "green" resulting in a significant reduction of plastic material as well as of manufacturing and disposal costs.