Vacuum Pack Sheet Layout for Printing and Stackable Display
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Solution Overview
Problem
Vacuum packaging methods face challenges in combining visual appeal with marketing demands due to deformation of thermoformable films, leading to high costs and stacking difficulties, and existing solutions like additional labeling or secondary packaging increase costs and material usage.
Innovation Solution
A method involving a container with a thermoformable first sheet and a non-thermoformable second sheet, where the first sheet is deformed to adhere to the container and product while the second sheet remains partially free, allowing for integrated labeling and easy stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a thermoformable sheet is used for vacuum packaging, then visual appreciation of the pack integrity is improved, but printing images or text on the film becomes difficult due to deformation during packaging
Solution Approach 1:
The packaging system is divided into two separate sheets: a first thermoformable sheet for vacuum packaging that provides visual appeal, and a second non-thermoformable sheet for printing information. This segmentation allows each sheet to fulfill its specific function without interference - the thermoformable sheet can deform during vacuum packaging while the separate printable sheet remains flat and suitable for accurate printing.
2Ease of manufacture
If all images and text are placed on the container, then printing is simplified, but stacking and display becomes difficult due to deformation of the thermoformed sheet towards the inside of the container
Solution Approach 1:
The solution moves the printable information from the deforming thermoformed sheet to a separate second sheet that is positioned in a different spatial dimension - extending over the upper mouth of the container rather than being on the container surface. This dimensional change allows the information to remain flat and planar while the thermoformed sheet deforms inward, enabling both accurate printing and proper stacking.
3Adaptability or versatility
If an additional label is applied over the vacuum pack, then marketing information can be displayed, but production line cost increases due to need for additional labelling machine
Solution Approach 1:
The method merges the vacuum packaging function and the information display function into a single integrated structure. The second non-thermoformable sheet is positioned and sealed together with the first thermoformable sheet in the same packaging operation, eliminating the need for a separate labeling machine. This combining of functions reduces production line complexity while maintaining marketing versatility.
4Ease of operation
If a cardboard or paperboard wrapper is used, then packs with flat upper face for easy stacking are obtained, but production line cost and material usage increase
Solution Approach 1:
The invention changes the material parameter of the upper packaging layer from traditional cardboard or paperboard to a non-thermoformable plastic sheet. This parameter change allows the material to maintain flatness for easy stacking while being processable in the existing vacuum packaging line without requiring secondary packaging equipment. The plastic sheet can be heat-sealed directly to the container flange, eliminating the need for separate cardboard wrapping operations.
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
Combines the advantages of vacuum packaging with traditional packs at lower costs by using a single operating step, reducing production line and material expenses while maintaining visual appeal and stackability.
Implementation Method 1
which increased its deformability
Implementation Method 2
The pressure difference may be obtained either by only creating the vacuum at the first face, or by also feeding compressed air at the second face
Implementation Method 3
a sheet of thermoplastic material is made to adhere to the product, and to the inside of the container
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A method for making a pack wherein a thermoformable first sheet (7) and a second sheet (8) smaller than the first sheet are positioned over a container (2) in which a product (1) is inserted, a fixing step for fixing the first sheet (7) and the second sheet (8) to a perimetric portion (33) of the container (2), and a deforming step during which the first sheet (7) is thermoformed causing the first sheet (7) to partially move away from the second sheet (8) towards the product (1). At the end of the deforming step the second sheet (8) is fixed to the first sheet (7) at the perimetric portion (33) of the container and extends across part of the upper mouth of the container (2), the upper mouth being at least partially free of the second sheet (8).