Paperboard-Plastic Container Rim Structure for Thin Foil Strength
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Solution Overview
Problem
Existing containers with paperboard and plastic layers are costly due to thick plastic requirements for strength, and the layers are difficult to separate, complicating recycling.
Innovation Solution
A container design with a reduced thickness inner plastic foil layer and a rolled-up paperboard rim portion, allowing for a thinner plastic layer and easier separation of layers, achieved through thermoforming and strategic use of adhesives and recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick plastic foil layer is used to ensure structural strength, then the container maintains adequate strength, but the plastic content increases and costs increase
Solution Approach 1:
The patent combines paperboard and plastic foil layers to create a composite container structure. The paperboard provides structural strength and rigidity, while the thin plastic foil layer provides barrier properties and seals the container. This composite approach allows the plastic layer to be much thinner than if plastic alone were used, reducing plastic content by up to 70% while maintaining overall container strength.
Solution Approach 2:
The container is divided into distinct functional layers: an outer paperboard layer for structural support and an inner plastic foil layer for sealing and barrier properties. This segmentation allows each material to be optimized for its specific function, enabling the plastic layer to be thin since it only needs to provide sealing rather than structural strength.
2Strength
If a thick plastic foil layer is used to ensure structural strength, then the container maintains adequate strength, but production costs increase
Solution Approach 1:
By using a composite structure with paperboard and thin plastic foil, the patent reduces material costs significantly. The paperboard is generally less expensive than thick plastic, and the thin foil layer requires less plastic material. This composite approach lowers production costs while maintaining the required structural strength for container applications.
3Strength
If adhesive is applied extensively to bond plastic foil to paperboard, then the layers are strongly bonded, but separation becomes difficult for recycling
Solution Approach 1:
The adhesive is applied selectively at specific locations rather than across the entire surface. The patent specifies that adhesive is applied at the rolled-up rim portion where the plastic foil meets the paperboard, creating a strong localized bond that maintains container integrity during use. This localized bonding approach allows the layers to be separated more easily for recycling compared to extensive adhesive coverage.
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
Reduces plastic content by up to 70% while maintaining structural integrity, facilitating easier recycling and lowering production costs.
Implementation Method 1
the term 'thermoforming' should be understood as a process where a plastic sheet or foil is heated and then inserted into a mould where it is formed into a shape defined by the mould
Implementation Method 2
strategic use of adhesives and recesses
Data Source
AI summary
A container comprising a bottom and a sidewall extending upwards from the bottom and terminating at an upper free edge, said upper free edge of the sidewall forming an opening of the container, said sidewall and said bottom comprising an outer paperboard layer and a thin inner plastic foil layer, formed in a thermoforming operation, said upper free edge of the sidewall comprising a rim portion extending past the outer surface of the paperboard layer of the sidewall. The rim portion comprises a rolled up portion of an upper portion of the outer paperboard layer of the sidewall, said rolled up portion being covered by a portion of the thin inner plastic foil layer. In this way, a stiff upper rim is provided, while allowing the use of a very thin inner plastic foil layer.