Foamed Molded Fiber Packaging With High-Solids Drying Reduction
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Solution Overview
Problem
Conventional packaging units made of moulded pulp require high water content and intensive drying processes, leading to high energy consumption and manufacturing costs, while also lacking sustainability and design flexibility.
Innovation Solution
The use of a foamed mouldable fiber material with a high solid content (>35% by weight) and a foaming agent, such as SLES, SDS, or ALS, reduces water requirements in the drying process and enhances product strength, homogeneity, and sustainability by incorporating recycled paper fibers and non-wood lignocellulosic biomass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional moulded pulp material with low solid content is used, then the material is easy to form and process, but the energy consumption and manufacturing costs increase due to intensive drying required to remove large amounts of water
Solution Approach 1:
The patent changes the key parameter of solid content in the moulded pulp material from conventional low levels (<30% by weight) to high levels (>35% by weight, preferably >40% by weight). This parameter change reduces the water content that needs to be removed during drying, thereby significantly reducing energy consumption and manufacturing costs while maintaining formability of the material
Solution Approach 2:
The patent introduces foamed mouldable fiber material with controlled porosity created by gas bubbles distributed throughout the fiber matrix. This porous structure allows the material to achieve high solid content while maintaining mouldability and formability, as the gas pockets provide space that reduces water content without compromising the material's ability to be formed into packaging units
2Ease of manufacture
If high water content is used in conventional moulded pulp, then the material remains mouldable and formable, but the drying process becomes more intensive and costly
Solution Approach 1:
The patent optimizes the solid content parameter to >35% by weight (preferably >40% by weight), which strikes an optimal balance between maintaining mouldability and reducing drying requirements. This parameter optimization improves manufacturing efficiency by reducing the time and energy needed for drying while ensuring the material remains sufficiently mouldable for forming packaging units
3Quantity of substance
If conventional packaging units are made with standard fibre content, then the material is readily available, but the product strength and insulation properties are insufficient
Solution Approach 1:
The patent creates a composite material structure by incorporating gas bubbles (foaming agent) within the fiber matrix, forming a foamed mouldable fiber material. This composite structure increases the effective fiber material content and improves product strength and insulation properties, as the gas pockets provide thermal insulation while the denser fiber network enhances mechanical strength
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
This approach significantly reduces energy costs, improves product strength and appearance, allows for more efficient use of raw materials, and enables more flexible designs with improved insulation and reduced material needs, while being fully recyclable and environmentally friendly.
Implementation Method 1
mouldable pulp that is used for the forming of the packaging unit in a manufacturing process comprises a foamed mouldable fiber material having a fiber material and a foaming agent
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a packaging unit (2) made of moulded pulp for products like eggs (P) and a method for manufacturing such packaging unit. The packaging unit according to the present invention comprises: - a carrier part (10) having a length, a width and a depth; and - one or more product compartments (48) that are provided in the carrier and are configured for receiving a product, wherein the moulded pulp comprises a foamed moulded fiber material, comprising a fiber material and a foaming agent, and having a solid content of the fiber material in the packaging unit abot 35% by weight.