Double-Layer Foamed Paper Containers for Insulation and Printing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional paper containers face issues with thermal insulation, deformation due to high drying temperatures, and poor printing effects from foam layers, while paper cups without foam layers offer poor thermal insulation and are inconvenient to hold.

Innovation Solution

A double-layered foamed paper container is manufactured by applying two foaming materials with different coating thicknesses, dried at lower temperatures, and then heated to form layers with adjustable thicknesses, allowing for thermal insulation, heat retention, and waterproof properties, with a smooth surface for printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick foaming material coating is applied to achieve thermal insulation effect, then thermal insulation performance is improved, but drying time increases and production efficiency decreases

Engineering Contradiction:

Improvethermal insulation effectVSAvoiddrying time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The foaming material coating is divided into two separate layers (first foaming material layer and second foaming material layer) that are applied and dried independently. This segmentation allows each layer to be dried more quickly while maintaining the required total thickness for thermal insulation, thereby resolving the contradiction between insulation performance and drying time.

Inventive Principle:

Principle #1Segmentation

2Productivity

If high drying temperature is used to speed up drying process, then drying time is reduced, but paper container deforms

Engineering Contradiction:

Improvedrying speedVSAvoidpaper container deformation

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The drying process is segmented into two separate drying stages, one for each foaming material layer. This allows the use of moderate temperatures throughout the process, preventing paper deformation while still achieving efficient drying through the cumulative effect of two drying cycles.

Inventive Principle:

Principle #1Segmentation

3Reliability

If foam layer is applied to provide thermal insulation, then thermal insulation effect is improved, but printing effect deteriorates due to large holes in foam structure

Engineering Contradiction:

Improvethermal insulation effectVSAvoidprinting effect

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The double-layered foaming structure provides different local qualities: the first layer provides thermal insulation with its foamed structure, while the second layer provides a smooth printing surface. This local differentiation resolves the contradiction by assigning different functions to different parts of the coating system.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses a composite structure of two different foaming materials (or the same material with different properties) where the outer layer specifically provides a smooth surface for printing while the inner layer provides thermal insulation. This composite approach allows both printing quality and thermal insulation to be optimized simultaneously.

Inventive Principle:

Principle #40Composite materials

4Reliability

If foam layer is applied to prevent water penetration, then waterproof effect is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvewaterproof effectVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The waterproofing function is segmented into two layers, with the outer layer providing the primary waterproof barrier and the inner layer providing additional protection. While this adds a layer to the process, each layer can be applied using standard coating equipment, so the increase in complexity is manageable and offset by the improved waterproof performance.

Inventive Principle:

Principle #1Segmentation

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 method enables efficient production of containers that are easy to process, provide effective thermal insulation and heat retention, and allow for good printing, suitable for both hot and cold drinks, while avoiding deformation and sticking during drying.

Implementation Method 1

heating the first foaming material and the second foaming material to foam into a first foam layer and a second foam layer respectively

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

heating the first foaming material and the second foaming material to foam into a first foam layer and a second foam layer respectively

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

drying the first foaming material at a temperature lower than a foaming temperature of the first foaming material

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20250332803A1Double-layered foamed paper container and manufacturing method thereof

Publication Date: 2025.10.30 CHANG CHING WEN

AI summary

The present invention provides a double-layered foamed paper container and a manufacturing method thereof. The manufacturing method of the double-layered foamed paper container includes following steps: applying first foaming material, primary drying, applying second foaming material, secondary drying and heating and foaming. The double-layered foamed paper container includes: a paper container body, having a circumferential wall and defining a receiving space, a first foam layer disposed on at least a portion of a side of the circumferential wall opposite to the receiving space.