Cellulose Ester Fiber Packaging for Air Permeability and Biodegradability
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Solution Overview
Problem
There is a need for environmentally non-persistent packaging materials that exhibit desirable properties such as air permeability and stiffness, particularly for food and beverage containers, while also ensuring minimal environmental impact upon disposal, as existing synthetic fibers are persistent in the environment.
Innovation Solution
A composition comprising cellulose fibers and cellulose ester staple fibers, co-refined with a denier per filament of less than 3 and a cut length of less than 6 mm, which are crimped, providing enhanced air permeability and thickness compared to 100% cellulose compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If synthetic fibers (polyester or polyolefins) are added to enhance air permeability, thickness, or stiffness, then the desired physical properties are improved, but environmental persistence increases
Solution Approach 1:
The patent changes the chemical composition parameters by using cellulose ester fibers with specific denier per filament (DPF) values and cut lengths, transforming the material properties to achieve both performance and environmental goals
Solution Approach 2:
The patent creates a composite material system blending cellulose fibers with cellulose ester staple fibers, combining the biodegradability of cellulose with the enhanced physical properties of cellulose esters to resolve the contradiction between performance and environmental persistence
2Strength
If cellulose ester staple fibers with low DPF and crimped structure are used, then air permeability and thickness are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent specifies precise parameter ranges for cellulose ester staple fibers (DPF less than 3, cut length less than 6 mm, crimped structure) to achieve desired thickness and air permeability while maintaining manufacturability through defined specifications
3Length of stationary object
If higher basis weight is used to increase thickness, then thickness is improved, but material consumption and environmental impact increase
Solution Approach 1:
The patent changes the fiber composition parameters by incorporating cellulose ester staple fibers with specific DPF and crimp characteristics, achieving greater thickness per unit weight through optimized material structure rather than increased material quantity
Solution Approach 2:
The patent employs a composite fiber blend that achieves enhanced thickness at lower basis weights through the synergistic effects of cellulose ester fiber morphology, reducing overall material consumption while meeting thickness requirements
Data Source
AI summary
Containers and lids made from cellulose fibers and cellulose ester fibers are provided that have enhanced air permeability, stiffness, R-heat insulation values, or thickness at equivalent grammage basis weights are provided, or alternatively, maintaining one or more of these properties while lowering the basis weight of the containers or lids. The container and lids with this synthetic fiber can be biodegradable when made with cellulose ester fibers having a degree of substitution of not more than 2.5. Examples of such containers are food packaging such as hot or cold delivery boxes.