Adhesive-Free Multi-Layer Insulative Sheet for Recyclable Containers
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Solution Overview
Problem
Current polymeric materials for insulating containers face challenges in achieving a balance between insulative properties, puncture resistance, recyclability, and microwavability, often compromising on one or more of these features due to design limitations.
Innovation Solution
A multi-layer sheet comprising an insulative cellular non-aromatic polymeric material, a polymeric-lamination layer, and a printed film layer, formed through an extrusion lamination process, which is adhesive-free and uses regrind to enhance recyclability and reduce waste, while maintaining high insulative and puncture resistance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to couple the film layer and insulative cellular polymeric material, then bonding strength is improved, but recyclability and microwavability deteriorate
Solution Approach 1:
The patent removes adhesive from the multi-layer construction entirely, replacing it with a polymeric lamination layer that provides bonding through material compatibility and extrusion lamination rather than adhesive bonding. This extraction of the harmful adhesive element enables both recyclability and microwavability while maintaining structural integrity.
Solution Approach 2:
The patent changes the bonding mechanism from chemical adhesive bonding to physical extrusion lamination, where the polymeric lamination layer is extruded between the film layer and insulative cellular material. This parameter change in the bonding method eliminates adhesive-related restrictions on recycling and microwaving while achieving sufficient bonding strength.
2Strength
If dense polymeric material is used to improve puncture resistance, then puncture resistance is improved, but insulative properties and density reduction deteriorate
Solution Approach 1:
The patent applies different material densities to different layers: the film layer and polymeric lamination layer provide structural strength and puncture resistance, while the insulative cellular material provides low density and thermal insulation. This local differentiation of material properties allows each layer to optimize its function without compromising the other.
Solution Approach 2:
The patent creates a composite multi-layer structure combining dense polymeric materials (film layer and lamination layer) with low-density cellular material. The composite structure achieves both high puncture resistance from the dense outer layers and superior insulative properties from the cellular core, resolving the contradiction between strength and insulation.
3Adaptability or versatility
If regrind is incorporated to enhance recyclability, then recyclability is improved, but manufacturing consistency and quality may deteriorate
Solution Approach 1:
The patent incorporates regrind (recycled polymeric material) into the film layer and/or polymeric lamination layer production, recovering and reusing material that would otherwise be waste. This approach enhances recyclability while the controlled incorporation process maintains manufacturing consistency through proper blending and processing parameters.
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 provides a container with improved rigidity, reduced density, and enhanced insulative properties, along with high puncture resistance and recyclability, effectively addressing the limitations of existing materials.
Implementation Method 1
an insulative cellular non-aromatic polymeric material
Implementation Method 2
formed through an extrusion lamination process
Data Source
AI summary
A multi-layer sheet includes an insulative cellular non-aromatic polymeric material, a film, and a polymeric-lamination layer. The insulative cellular non-aromatic polymeric material may be formed from a polymeric formulation comprising a base resin blend and a physical nucleating agent.