Thermoforming Porous Infusion Packets via Cryogenic Embrittlement
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Solution Overview
Problem
Conventional infusion packets, such as tea bags, are limited by their flat shape, restricting the movement of infusible materials and resulting in suboptimal infusion performance, and existing three-dimensional designs face challenges in manufacturing and porosity issues during thermoforming.
Innovation Solution
A process involving thermoforming of a thermoplastic polymer film with an embossed surface to create porous three-dimensional shapes for infusion packets, using a polymer film that is not necessarily porous before thermoforming, ensuring the thermoformed material remains permeable and minimizes particle leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flat infusion packets are used, then manufacturing is simple, but infusion performance is limited due to restricted material movement
Solution Approach 1:
The patent transitions from flat two-dimensional infusion packets to three-dimensional tetrahedral packets. This dimensional change allows infusible material to move freely in three dimensions, significantly improving infusion performance while maintaining manufacturability through specialized sealing apparatus
2Shape
If tetrahedral packets are manufactured by making mutually perpendicular transverse seals, then three-dimensional shape is achieved, but manufacturing apparatus is ill-suited for other shapes
Solution Approach 1:
The sealing process is divided into sequential stages: first sealing to form a tube, then second sealing to create the tetrahedral shape. This segmentation allows the same apparatus to potentially produce different shapes by varying the sealing patterns, improving versatility while maintaining three-dimensional form
3Shape
If GB 2 408 252 manufacturing method is used with heat and/or moisture application, then three-dimensional shapes are formed, but folding and gathering occurs causing non-porous areas and material trapping
Solution Approach 1:
The patent uses cryogenic temperatures (liquid nitrogen at -196°C) to embrittle the filter material, allowing it to be formed into three-dimensional shapes without folding or gathering. This parameter change (temperature) enables precise shape formation while maintaining uniform porosity throughout the packet structure
4Ease of manufacture
If conventional paper material is used, then traditional manufacturing is possible, but thermoforming is not suitable due to material properties
Solution Approach 1:
The patent applies cryogenic temperature treatment to convert flexible filter material into an embrittled state suitable for thermoforming. This parameter change enables the material to be formed into complex three-dimensional shapes with sharp features while maintaining structural integrity and porosity
5Adaptability or versatility
If thin thermoplastic material is heated for thermoforming, then deformation is possible, but material may tear or perforations may enlarge causing particle leakage
Solution Approach 1:
The patent uses cryogenic temperatures to embrittle the material before thermoforming, allowing deformation at lower temperatures that do not cause tearing or perforation enlargement. This parameter change enables thermoforming while maintaining material integrity and preventing particle leakage
6Shape
If heating is applied during thermoforming, then material deformation is achieved, but perforations may close reducing porosity
Solution Approach 1:
The patent uses cryogenic temperatures instead of heating for thermoforming. This parameter change allows the material to be deformed into three-dimensional shapes without thermal closure of perforations, maintaining uniform porosity throughout the formed structure
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
Enables the production of infusion packets with varied three-dimensional shapes that maintain porosity and uniformity, enhancing infusion performance and appearance while overcoming the limitations of traditional materials and manufacturing methods.
Implementation Method 1
heating the material to a temperature which is sufficient to allow the thermoplastic material to deform under thermoforming stresses
Implementation Method 2
thermoforming portions of the first sheet into a three-dimensional shape... the thermoformed portions of the first sheet are porous
Data Source
Figure 1~2
AI summary
The present invention relates to a process for the manufacture of infusion packets, the process comprising: . (a) providing a first sheet of thermoplastic material (2) which is porous or non- porous; . (b) thermoforming portions of the first sheet into a three- dimensional shape; . (c) providing a second sheet of material; . (d) dosing an infusible substance into the thermoformed portions of the first sheet or onto the second sheet; . (e) sealing the first and second sheets together to form pockets containing the infusible substance such that each pocket includes at least one thermoformed portion of the first sheet; . (f) severing the pockets at the seals to form infusion packets each having a chamber containing the infusible substance,