Hot-Folding Planar Composite Container Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional food storage containers like cans and glass jars face issues such as inefficient storage, high energy consumption, and safety hazards during opening, while existing planar composite containers have defects leading to reduced shelf life due to mechanical stress and oxygen entry.
Innovation Solution
A process for producing containers using a planar composite with a carrier layer, a barrier layer of plastic, and multiple layers of thermoplastic plastics, where the layers are folded and joined to form edges, with one layer being heated above its melting temperature for sealing, reducing the need for intense disinfection and improving storage efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cans and glass jars are used for food storage, then food preservation is achieved, but storage space efficiency is poor and energy consumption is high
Solution Approach 1:
The patent changes the physical state of the thermoplastic layers from solid to melt during the folding process by heating them above their melting temperature. This parameter change enables the plastic layers to conform to the desired container shape and create sealed joints, achieving efficient container formation with reduced material waste and lower energy consumption compared to traditional canning methods
Solution Approach 2:
The patent employs a composite structure consisting of a carrier layer (cardboard or paper) combined with thermoplastic layers. This composite material approach allows the container to achieve both structural integrity and sealing properties, improving storage efficiency while reducing the energy and resources required for production and transportation compared to traditional metal or glass containers
2Ease of manufacture
If planar composite containers are produced with sharp folds and creases, then container formation is achieved, but defects such as cracks and unsealed pockets occur leading to reduced shelf life
Solution Approach 1:
The patent applies heating to raise the temperature of the thermoplastic layers above their melting point during the folding process. This parameter change softens the plastic, allowing it to flow and seal smoothly around sharp folds and creases, eliminating defects like cracks and unsealed pockets that would otherwise compromise shelf life
Solution Approach 2:
The patent utilizes the phase transition of the thermoplastic layers from solid to melt during folding, and then back to solid upon cooling. This phase transition enables the plastic to adapt to complex geometries and create hermetic seals at fold lines, ensuring container integrity and long shelf life without the defects associated with cold-forming
3Productivity
If the container is filled and sealed quickly, then production speed is improved, but the risk of defects and contamination increases
Solution Approach 1:
The patent performs the sealing action during the folding process itself, before the container is filled with foodstuff. By heating and sealing the thermoplastic layers at the fold lines during formation, the container achieves hermetic sealing in advance, eliminating the need for separate sealing steps and reducing the risk of contamination while maintaining high production speed
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 process results in containers with a longer shelf life, reduced energy consumption, and improved production speed, while minimizing defects and oxygen entry, thus enhancing food storage quality and safety.
Implementation Method 1
at least one of the at least two layers of thermoplastic plastic in step b. is heated above the melting temperature
Implementation Method 2
at least one of the at least two layers of thermoplastic plastic in step b. is heated above the melting temperature
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates generally to a process for the production of a container surrounding an interior, comprising the steps a. provision of a planar composite comprising i. a carrier layer, ii. a barrier layer of plastic joined to the carrier layer, iii. at least two layers of thermoplastic plastic KSa and KSw which are provided on the side of the barrier layer of plastic facing away from the carrier layer, wherein at least one of the at least two layers of plastic being a plastics mixture of at least two plastics, b. folding of the planar composite to form a fold with at least two fold surfaces adjacent to one another and c. joining of respectively at least a part region of the at least two fold surfaces to form a container region, and a container obtainable by this process.