Fluid Pouch Inner Microstructure for 99% Extraction
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Solution Overview
Problem
Existing fluid pouches become obsolete and waste a significant amount of fluid as they can only extract a limited percentage of the original content before becoming unusable, with typically 20% or more remaining when they are discarded.
Innovation Solution
A flexible container with a first polymeric sheet featuring an inner microstructure and a second sheet without microstructure, where the aerial microstructure surface area density (AMSAD) is between 1% and 15%, allowing for efficient fluid extraction via pumps, air pressure, or gravity, thereby delaying obsolescence and maximizing fluid usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional smooth pouches are used, then manufacturing is simple and成本低, but fluid extraction efficiency is poor with 20% or more remaining
Solution Approach 1:
The pouch incorporates a microstructured inner surface with controlled porosity and surface area (AMSAD 1-15%) that facilitates complete fluid extraction. The microstructure acts as a porous-like surface that maintains contact with fluid residues, enabling extraction of up to 99% of stored fluid compared to conventional smooth surfaces that leave 20% or more.
Solution Approach 2:
The invention transitions from a conventional two-dimensional smooth inner surface to a three-dimensional microstructured surface. This dimensional change increases the effective surface area (AMSAD) within a controlled range (1-15%), creating more contact points for fluid extraction while maintaining manufacturability through embossing or molding techniques.
2Loss of substance
If the pouch space shrinks significantly during extraction, then more fluid can be removed, but wrinkles form and extraction stops
Solution Approach 1:
The microstructured inner surface maintains structural stability during extraction by distributing mechanical stresses across numerous micro-features. This porous-like structure prevents wrinkle formation even as the pouch shrinks, allowing extraction to continue until 99% of fluid is removed without the structural failure that occurs in conventional smooth pouches.
Solution Approach 2:
The pouch structure dynamically adapts during extraction by utilizing the flexible microstructured surface to accommodate volume changes. The microstructure allows the pouch to shrink and expand without forming permanent wrinkles, maintaining extraction capability throughout the entire fluid removal process.
3Loss of substance
If AMSAD is increased beyond 15%, then fluid extraction improves, but manufacturing complexity and cost increase
Solution Approach 1:
The invention optimizes the AMSAD parameter within the specific range of 1-15%, representing the optimal balance between extraction efficiency and manufacturability. This parameter optimization ensures that the microstructure provides sufficient surface area for 99% fluid extraction while remaining feasible to manufacture through conventional embossing or molding processes, avoiding the excessive complexity that would arise with higher AMSAD values.
Data Source
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AI summary
Disclosed is a pouch (also called a flexible container) for holding fluid, the pouch including: (a) a first polymeric sheet including a first inner body and a first outer surface, the first inner body including a first inner surface and inner microstructure extending from the first inner surface, the first inner body defining an aerial microstructure surface area density (AMSAD) between 5% and 15%; (b) a second polymeric sheet including a second inner surface and a second outer surface. The second polymeric sheet may be joined with the first polymeric sheet such that the first inner body and the second inner surface form an air-tight fluid chamber therebetween. The second polymeric sheet may lack microstructure extending from the second inner surface. The first inner surface, the first outer surface, the second inner surface, and the second outer surface may be smooth and non-recessed.