Cellular Polymeric Container Material for Insulation and Impact
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Solution Overview
Problem
Current polymeric materials for containers lack a balance between insulation and impact resistance, often resulting in high density or inadequate insulation properties.
Innovation Solution
A polymeric material comprising a blend of high-density polyethylene-based resins and cell-forming agents, such as chemical and physical blowing agents, is extruded to create a low-density, insulated cellular non-aromatic polymeric material with a multi-layer structure, enhancing both insulation and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional polymeric materials are used for containers, then manufacturing is simple, but insulation performance is inadequate
Solution Approach 1:
The patent applies porous materials by incorporating a cellular structure within the polymeric container wall. This cellular structure contains cells with walls and interconnected voids that trap air pockets, providing thermal insulation while maintaining the overall structural integrity of the container. The porous cellular structure reduces thermal conductivity without requiring additional insulating layers.
Solution Approach 2:
The patent applies composite materials by creating a multi-phase polymeric system consisting of a continuous polymeric phase combined with a cellular structure phase. This composite structure integrates the structural benefits of solid polymeric material with the insulating properties of air-filled cells, achieving both mechanical strength and thermal insulation in a single material system.
2Temperature
If density is reduced to improve insulation, then insulation performance increases, but impact resistance deteriorates
Solution Approach 1:
The patent applies local quality by creating regions of different density and structure within the container wall. The cellular structure provides localized insulation properties in the core regions, while the polymeric matrix and cell walls maintain localized structural strength. This spatial variation in material properties allows the container to achieve both insulation and impact resistance simultaneously.
Solution Approach 2:
The cellular porous structure provides insulation through trapped air pockets while the polymeric cell walls and interconnected structure distribute impact forces throughout the material. The porous structure reduces density for insulation while the polymeric framework maintains mechanical integrity for impact resistance.
3Temperature
If cellular structure is introduced to reduce density, then insulation improves, but structural strength worsens
Solution Approach 1:
The cellular porous structure provides insulation through trapped air pockets while the polymeric cell walls and interconnected structure distribute impact forces throughout the material. The porous structure reduces density for insulation while the polymeric framework maintains mechanical integrity for impact resistance.
Solution Approach 2:
The patent applies parameter changes by controlling the cellular structure parameters including cell size, cell wall thickness, and porosity ratio. By optimizing these parameters, the material achieves the desired balance between insulation performance (requiring high porosity) and structural strength (requiring sufficient solid material). The cell-forming agents enable precise control over these structural 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 achieves a low-density, insulated cellular polymeric material that is resistant to impact forces, suitable for improved container applications while maintaining effective insulation.
Implementation Method 1
The cell-forming agent can include a chemical nucleating agent and a physical blowing agent
Implementation Method 2
a blend of polymeric resins and cell-forming agents is mixed and extruded or otherwise formed to produce an insulated cellular non-aromatic polymeric material
Data Source
AI summary
A formulation for producing a polymeric material including high-density polyethylene, a chemical blowing agent, and other optional components is described.