Heat-Activated Insulating Packaging With Expandable Air-Gap Walls
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Solution Overview
Problem
Existing thermally insulated containers for food and beverages often require additional assembly steps and storage space, and they may not effectively manage heat transfer, leading to discomfort for consumers when handling hot or cold items.
Innovation Solution
A double-wall container design featuring a die cut blank coated with a thermally expandable material that activates upon temperature change, providing insulation and rigidity while maintaining a slim profile and efficient assembly, by applying the expandable material between the container and the blank, which expands to create an air gap for thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermally insulated container uses a double-wall design with additional assembly steps, then thermal insulation performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The thermally expandable material is applied to the container surface in advance during manufacturing, before the container is put into service. The material remains in a compact state during storage and transport, then automatically expands when exposed to thermal energy from hot or cold contents, forming the insulating air gap without requiring additional assembly steps by the consumer.
Solution Approach 2:
The insulating structure changes its physical state based on temperature parameters. The thermally expandable material transitions from a compact low-volume state at ambient temperature to an expanded high-volume state when exposed to thermal energy, creating the insulating air gap between container walls dynamically in response to temperature changes.
2Reliability
If a thermally insulated container uses traditional insulation materials, then thermal insulation is provided, but the container thickness increases and slim profile is lost
Solution Approach 1:
The insulating structure changes its physical state based on temperature parameters. The thermally expandable material transitions from a compact low-volume state at ambient temperature to an expanded high-volume state when exposed to thermal energy, creating the insulating air gap between container walls dynamically in response to temperature changes.
Solution Approach 2:
The thermally expandable material is applied as a coating layer on the container surface, nesting the insulating function within the container wall structure itself. When expanded, the material creates an air gap that provides insulation while maintaining a relatively thin overall container profile compared to traditional rigid insulation layers.
3Reliability
If thermally expandable material is applied to container, then thermal insulation and rigidity are enhanced, but manufacturing process complexity increases
Solution Approach 1:
The thermally expandable material contains expandable particles or bubbles that create a porous structure when expanded. This porous expanded structure provides both thermal insulation through trapped air pockets and mechanical rigidity through the three-dimensional network, achieving dual functionality from a single material application.
Solution Approach 2:
The solution uses a composite approach by applying thermally expandable material (such as expandable microspheres in a binder) to the container surface. This composite material system combines the properties of the base container material with the expandable particles, providing both insulation and structural reinforcement when activated.
4Reliability
If additional insulation layers are added to container, then thermal conductivity is reduced, but weight and material quantity increase
Solution Approach 1:
The insulating structure changes its physical state based on temperature parameters. The thermally expandable material transitions from a compact low-volume state at ambient temperature to an expanded high-volume state when exposed to thermal energy, creating the insulating air gap between container walls dynamically in response to temperature changes.
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 solution effectively reduces heat transfer, maintains the container's slim profile, and enhances user comfort by minimizing thermal conductivity and providing mechanical strength, thus keeping contents hot or cold for longer and reducing material thickness.
Implementation Method 1
The material may be adapted to be expanded to provide thermal insulation... The material is expanded in response to a determined temperature
Implementation Method 2
provide thermal insulation... effectively reduces heat transfer... maintaining a slim profile... minimizing thermal conductivity
Data Source
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AI summary
A package or container includes a side wall, the side wall having an inner surface and an outer surface. At least one of the inner surface or the outer surface of the side wall may be at least partially coated by a layer of a thermally expandable material. The material may be adapted to be expanded to provide thermal insulation.