Vacuum-Molded Fiber Containers With Barrier Coatings

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Solution Overview

Problem

Current fiber-based packaging technologies are not well-suited for meat and poultry containers, prepared food, produce, microwavable food containers, and lids for beverage containers, as they lack the necessary moisture and vapor barriers to maintain structural rigidity and prevent contamination.

Innovation Solution

The development of novel fiber-based packaging solutions that incorporate geometric features and chemical formulations with moisture, oil, and vapor barriers, along with enhanced bonding agents, to create rigid and durable containers that can withstand extended shelf life and microwave heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional fiber-based packaging is used, then biodegradability and compostability are achieved, but moisture and vapor barrier properties are insufficient

Engineering Contradiction:

Improvemoisture and vapor penetrationVSAvoidstructural rigidity

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies composite materials by combining fiber-based base material with moisture and vapor barrier coatings. The molded fiber container serves as the structural base, while additional barrier layers are applied to provide moisture and vapor protection without compromising the biodegradable nature of the overall structure.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses thin film coatings applied to the molded fiber container to provide moisture and vapor barriers. These flexible barrier films conform to the container shape and provide the necessary protection while maintaining the lightweight and biodegradable characteristics of the fiber-based structure.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If plastic containers are used, then moisture and vapor barrier properties are excellent, but environmental sustainability is compromised

Engineering Contradiction:

Improvemoisture and vapor barrierVSAvoidenvironmental pollution

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameters by transitioning from synthetic plastic materials to natural fiber-based materials with added barrier coatings. This parameter change maintains the functional performance of moisture and vapor barriers while fundamentally altering the environmental impact from persistent pollution to biodegradability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs disposable molded fiber containers that are designed for single use but are environmentally benign. Unlike plastics that persist in the environment for centuries, these fiber-based containers decompose naturally after use, aligning with the principle of disposable objects that minimize long-term environmental harm.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If fiber-based packaging is used for meat containers, then biodegradability is achieved, but structural rigidity and durability are insufficient

Engineering Contradiction:

Improvestructural rigidityVSAvoidshelf life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent uses composite materials by combining molded fiber base material with protective barrier coatings. This composite structure provides the structural rigidity needed for meat containers while the barrier coatings extend shelf life by preventing moisture and vapor penetration, thereby resolving the contradiction between biodegradability and durability.

Inventive Principle:

Principle #40Composite materials

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

These solutions enable the creation of biodegradable and compostable containers that maintain structural integrity and prevent moisture and vapor penetration, effectively replacing plastic containers in various applications while ensuring food safety and environmental sustainability.

Implementation Method 1

a vacuum mold is drawn through a fiber-based slurry

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

incorporate geometric features and chemical formulations with moisture, oil, and vapor barriers

Methodology Applied

Scientific EffectMoisture barrier:

Data Source

PatentUS11248348B2Methods and apparatus for manufacturing fiber-based meat containers

Publication Date: 2022.02.15 FOOTPRINT INT LLC

AI summary

Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises a moisture barrier, an oil barrier, and a vapor barrier.