Process for forming an insulated container having artwork

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing insulated containers, such as cups, face challenges in achieving a balance between insulative performance, recyclability, high-quality graphics, chemical resistance, puncture resistance, frangibility resistance, microwavability, and resistance to leaching undesirable substances, with many failing to combine these features effectively.

Innovation Solution

The development of an insulative cup made from insulative cellular non-aromatic polymeric material, comprising a polypropylene base resin with high melt strength, cell-forming agents like carbon dioxide, and a slip agent, which allows for localized plastic deformation and direct printing of high-resolution graphics, while maintaining insulative characteristics and being recyclable.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional insulated container materials are used, then insulative performance is achieved, but recyclability and resistance to leaching undesirable substances deteriorate

Engineering Contradiction:

Improveinsulative performanceVSAvoidrecyclability and resistance to leaching

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent changes the material parameters by using food-grade polypropylene with specific molecular weight distribution (bimodal or multimodal) and controlled crystallinity (30-90%). This allows the material to maintain insulative properties while being recyclable and free from leaching concerns, as it meets food contact safety standards

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure by combining polypropylene base resin with functional additives including nucleating agents, blowing agents, and slip agents. This composite material achieves both insulative performance through the cellular structure and safety/recyclability through the food-grade polypropylene matrix

Inventive Principle:

Principle #40Composite materials

2Illumination intensity

If high-quality graphics are printed on the container surface, then aesthetic appearance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvegraphics qualityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent applies a release coating to the container surface before printing. This preliminary action creates a suitable substrate for high-quality graphics printing while maintaining a relatively simple manufacturing process. The release coating is applied in advance to enable subsequent printing operations without requiring complex surface preparation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent incorporates colorants and dyes into the polypropylene material itself or applies printed graphics on the release-coated surface. This allows for high-quality visual appearance through color variation and graphical design while maintaining manufacturing simplicity through integration with the molding or coating process

Inventive Principle:

Principle #32Color changes

3Strength

If the container structure is made more robust for puncture and frangibility resistance, then strength is improved, but weight and material usage increase

Engineering Contradiction:

Improvepuncture and frangibility resistanceVSAvoidcontainer weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent enhances strength locally at critical areas such as the bottom, rim, and handle by adjusting the cellular structure density and material distribution in these regions. The bulk of the container maintains lower density for weight efficiency, while localized reinforcement provides puncture and frangibility resistance where needed

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs curved and rounded structural features such as a rolled brim, curved handle attachments, and domed bottom geometry. These curved structures naturally resist puncture and fragmentation by distributing stress evenly, providing enhanced strength without requiring additional material or increasing weight

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 insulative cup achieves superior insulative performance, recyclability, resistance to punctures and frangibility, and microwavability, while minimizing material loss and leaching risks, thus overcoming the limitations of previous designs.

Implementation Method 1

cell-forming agents including primary and secondary nucleating agents and a blowing agent such as carbon dioxide gas that is injected into the resins to expand the resins and reduce density

Methodology Applied

Scientific EffectGas expansion: Bubble

Implementation Method 2

insulated container having a sleeve-shaped side wall... insulative cellular non-aromatic polymeric material is located between the graphics and the interior region

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9656793B2Process for forming an insulated container having artwork

Publication Date: 2017.05.23 BERRY PLASTICS CORP

AI summary

A container is formed to include and interior region and a mouth opening into the interior region. The container includes a floor, a side wall coupled to the floor to define the interior region between the floor and the side wall, and artwork on the side wall.