Cellular Polypropylene Insulated Container Material
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Solution Overview
Problem
Current polymeric materials for insulated containers lack effective insulation, recyclability, and resistance to punctures and heat, while also being prone to material breakdown in dishwashers and microwaves.
Innovation Solution
A polypropylene-based formulation with high melt strength, nucleating agents, and blowing agents is extruded to create a cellular non-aromatic polymeric material with localized plastic deformation, enabling enhanced insulation, recyclability, and resistance to punctures and heat exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymeric materials are used for insulated containers, then the container can be manufactured, but the insulation performance is insufficient and the material breaks down under heat and mechanical stress
Solution Approach 1:
The patent changes the physical and chemical parameters of the polymeric material by incorporating cell-forming agents that create a cellular structure with controlled cell size, shape, and distribution. This cellular structure provides thermal insulation while maintaining mechanical integrity under heat and stress conditions.
Solution Approach 2:
The patent creates a composite polymeric material combining base polymer with cell-forming agents and nucleating agents. This composite structure provides both insulation properties and enhanced durability, resisting breakdown under heat and mechanical stress while maintaining structural integrity.
2Temperature
If polymeric materials with high insulation are used, then thermal performance improves, but recyclability is compromised due to component segregation
Solution Approach 1:
The patent achieves homogeneity by integrating cell-forming agents directly into the polymeric resin matrix, creating a uniform cellular structure throughout the material. This homogeneous composition allows the entire material to be recycled together without segregation of components, maintaining both insulation performance and recyclability.
3Strength
If the polymeric material is designed for structural integrity, then resistance to punctures improves, but insulation performance may be reduced due to denser structure
Solution Approach 1:
The patent utilizes a porous cellular structure where gas-filled cells provide thermal insulation while the cell walls maintain structural strength. The nucleating agents control cell size and distribution to optimize both insulation performance and puncture resistance, creating a lightweight yet strong insulating material.
Solution Approach 2:
The patent applies local quality by creating regions with different cell densities and structures - denser cell walls provide strength and puncture resistance, while the overall cellular architecture maintains insulation performance. The material has varying local properties optimized for different functional requirements.
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 improved insulation, recyclability, and durability, allowing the material to maintain structural integrity under heat and mechanical stress, and can be recycled without segregation of components.
Implementation Method 1
cell-forming agents including at least one nucleating agent and a blowing agent such as carbon dioxide
Implementation Method 2
cell-forming agents including at least one nucleating agent
Implementation Method 3
A polypropylene-based formulation in accordance with the present disclosure is heated and extruded in two stages
Data Source
AI summary
A formulation includes a polymeric material, a nucleating agent, a blowing, and a surface active agent. The formulation can be used to form a container.