Two-Compartment Food Container with Inner Shoulder and Flexible Lids
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Solution Overview
Problem
Existing thermoformed plastic flanged containers for food, such as yoghurt pots, face challenges in manufacturing efficiency, handling difficulties, and structural integrity, particularly when produced in multipack formats or subjected to high stacking loads, due to thin side walls and brittle plastic materials.
Innovation Solution
A two-compartment container design featuring a thermoplastic hollow body with an inner shoulder defining a slope, allowing for easier stacking and handling, and flexible closure lids that prevent accidental opening, while reducing plastic material usage and enhancing mechanical strength through a decorative strip coverage and optimized flange design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the side wall thickness is reduced to lower cost, then the unit cost decreases, but the mechanical strength and rigidity deteriorate
Solution Approach 1:
The patent applies local quality by varying the wall thickness in different regions of the container. The bottom wall and flange maintain greater thickness for structural support, while the side walls use reduced thickness to minimize material usage. This localized differentiation allows cost reduction without compromising overall mechanical strength.
Solution Approach 2:
The patent employs composite material construction by combining thermoplastic material for the container body with foil materials for the closure lids. This composite approach allows each material to perform its optimal function - the thermoplastic provides structural integrity while the foil provides sealing - thereby achieving strength requirements with reduced overall material cost.
2Ease of manufacture
If conventional stacking is permitted with thin flanges, then manufacturing simplicity is maintained, but the container integrity under load deteriorates
Solution Approach 1:
The flange is designed with locally increased thickness compared to the side walls, creating a reinforced region that can withstand stacking loads. This local quality enhancement at the flange provides the necessary structural strength while maintaining simpler manufacturing processes for the overall container.
3Loss of substance
If deep cavity containers are formed with thin material, then material usage is reduced, but the rigidity and resistance to distribution rigors deteriorate
Solution Approach 1:
The container design uses local quality by concentrating material where structurally necessary - the bottom wall and flange have greater thickness for load-bearing functions, while the side walls use minimal thickness sufficient for containment. This allows deep cavity formation with reduced overall material usage while maintaining rigidity at critical locations.
4Ease of manufacture
If brittle plastic material is used for multipack containers, then manufacturing cost decreases, but the ease of separation and handling deteriorates
Solution Approach 1:
The patent applies segmentation by designing the multipack container with defined separation zones between individual containers. These zones allow for controlled breaking and separation of containers from the pack. The flange design includes features that facilitate clean separation while maintaining container integrity during the separation process.
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 enables the production of cost-effective, user-friendly, and robust two-compartment containers suitable for high-rate industrial processes, ensuring secure sealing and easy handling while maintaining mechanical strength and aesthetic appeal.
Implementation Method 1
the plastic sheet is heated and then drawn into a cavity such as by vacuum and/or pressure
Implementation Method 2
the plastic sheet is heated and then drawn into a cavity such as by vacuum and/or pressure
Implementation Method 3
a first flexible closure lid, sealed on a first annular surface formed on an interior face of the side wall... a second flexible closure lid, sealed on a second annular surface surrounding an upper opening of the container
Data Source
Figure 1~2
Figure 3~4B
Figure 5~6
AI summary
The container (1) for a dairy product or similar food composition is provided with a hollow body (2), a bottom (2a) and an opening (6) typically surrounded by a generally planar annular flange (7) connected to the top of the body. Two flexible closure lids (15, 20) are used to define with the side wall of the body an upper compartment that extends between the two lids. The lower compartment is filled with the food composition. The inner lid (15) has an annular outer portion which is in continuous annular contact with an inner shoulder of the side wall (4) and extends upwardly from a central covering portion. A spoon (18) or other solid content may be provided in the upper compartment, below the outer lid (20). Several identical containers (1) can be grouped in a pack with breakable junctions at an outer side edge of the flange.