Multilayer Food Container Reducing Hazardous Substance Elution
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Solution Overview
Problem
Conventional food containers made from synthetic resins, such as polystyrene, release hazardous environmental hormones that threaten human health, and existing alternatives like paper or foam containers have limitations in thermal barrier properties and production costs.
Innovation Solution
A food container with a multilayer structure featuring a foamed layer and a resin layer with a specific repeating unit, where the resin layer is laminated on one or both surfaces of the foamed layer, reducing the elution of hazardous substances and enhancing thermal resistance, compressive strength, and moldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a synthetic resin container is used for food storage, then the container provides light weight, strength, and ease of manufacturing, but hazardous environmental hormones are eluted from the container surface and contaminate food
Solution Approach 1:
The patent applies composite materials by creating a multilayer structure consisting of a foamed layer and a skin layer with specific molecular structure. The skin layer is formed by copolymerizing styrene with alpha-methylstyrene (5-20 mol%) and/or p-methylstyrene (5-20 mol%), creating a composite material system that combines the desirable properties of styrene (strength, rigidity) with the beneficial effects of the copolymer structure (reduced hazardous substance elution). This composite approach allows the container to maintain structural integrity while significantly reducing the elution of styrene dimers and trimers into food.
2Temperature
If paper or thick corrugated paper is used to wrap the container for thermal insulation, then heat insulation is improved, but production and processing costs increase due to separate manufacturing and waste
Solution Approach 1:
The patent merges the container structure with thermal insulation functionality by integrating a foamed layer directly into the container wall structure. The foamed layer is formed in-situ during the molding process, combining what were previously separate components (container body and insulation layer) into a single integrated structure. This eliminates the need for separate manufacturing and assembly of insulation materials, reducing production costs and simplifying the manufacturing process while providing effective thermal insulation.
Solution Approach 2:
The container wall structure is designed to serve multiple functions simultaneously: the skin layer provides structural strength and barrier properties, while the foamed layer provides thermal insulation. This multilayer structure achieves multi-functionality in a single integrated component, eliminating the need for separate insulation wraps and reducing the overall number of components and manufacturing steps.
3Temperature
If a foam sheet manufactured by foaming polystyrene resin is used for thermal resistance, then thermal insulation is improved, but styrene monomer is released during use and becomes harmful to human body
Solution Approach 1:
The patent applies parameter changes by modifying the molecular structure and composition of the polymer material. Specifically, the skin layer is formed by copolymerizing styrene with alpha-methylstyrene (5-20 mol%) and/or p-methylstyrene (5-20 mol%), which changes the chemical parameters of the material. This molecular-level parameter change reduces the release of styrene monomer while maintaining thermal resistance properties, as the copolymer structure stabilizes the material and reduces monomer migration during use.
4Productivity
If the container structure is simplified to reduce manufacturing complexity, then production efficiency is improved, but thermal barrier property and structural integrity may be compromised
Solution Approach 1:
The patent applies segmentation by dividing the container wall into distinct functional layers: a skin layer (0.1-5 mm thick) providing structural strength and barrier properties, and a foamed layer providing thermal insulation. This segmented structure allows each layer to be optimized for its specific function while being manufactured as an integrated component, maintaining both thermal barrier properties and structural integrity without compromising production efficiency.
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 multilayer structure improves thermal insulation, reduces hazardous substance elution, and maintains structural integrity and printability, providing a safer and more effective food storage solution.
Implementation Method 1
a foamed layer having an average cell size of 100 to 500 μm... having an excellent heat insulation
Implementation Method 2
an environmental hormone, which is a hazardous substance, is eluted from a surface of the synthetic resin container... the resin layer is formed of a resin having a repeating unit of Formula 1... reducing the elution of hazardous substances
Data Source
AI summary
The present invention relates to a food container with a reduced amount of elution of hazardous substances. As the food container according to the present invention has a structure in which a foamed layer and a PETG resin layer are laminated, compressive strength is improved and moldability is excellent, so that the food container may be provided in various sizes and shapes. Moreover, the present invention has a harmless effect to a human body due to a remarkably low amount of elution of hazardous substances.