Insulated Container Multi-Layer Polymeric Structure
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Solution Overview
Problem
Existing polymeric materials for containers lack effective insulation and weight stability when filled with cold liquids and exposed to humid environments, leading to condensation issues and structural deformation.
Innovation Solution
A polymeric material comprising an insulative cellular non-aromatic polymeric material, a polymeric lamination layer, and a film layer, formed through an extrusion lamination process, which provides improved rigidity and minimal weight gain when exposed to humidity, using polyethylene as a primary component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymeric materials are used for containers, then manufacturing is simple, but insulation performance is insufficient and weight stability deteriorates when filled with cold liquids in humid environments
Solution Approach 1:
The patent applies composite materials by combining multiple polymeric layers with distinct functions: an insulative cellular non-aromatic polymeric material layer for thermal insulation, a polymeric lamination layer for structural integrity, and a film layer for moisture barrier properties. This multi-layer composite structure resolves the contradiction by integrating different material properties to achieve both superior insulation performance and weight stability while maintaining manufacturing feasibility through extrusion lamination processes.
Solution Approach 2:
The patent implements local quality by assigning different functional properties to different layers of the container wall. The insulative cellular layer provides thermal insulation where needed, the lamination layer provides structural strength in critical areas, and the film layer provides moisture resistance at the outer surface. This localized functional distribution allows each layer to optimize its specific performance contribution while collectively solving the overall reliability issue.
2Object-affected harmful factors
If conventional polymeric materials are used, then material simplicity is maintained, but condensation occurs and structural deformation happens when exposed to humid environments with cold liquids
Solution Approach 1:
The patent uses composite materials to prevent condensation and structural deformation by creating a multi-functional barrier system. The hydrophobic film layer prevents moisture ingress that would cause condensation, while the insulative cellular layer reduces thermal bridging that leads to structural deformation. The polymeric lamination layer provides structural reinforcement throughout the container wall, collectively preventing these harmful effects.
Solution Approach 2:
The patent introduces intermediary layers between the container interior and exterior environments. The film layer acts as an intermediary moisture barrier preventing humid environment contact, while the insulative cellular layer serves as an intermediary thermal barrier reducing temperature differentials that cause condensation and deformation. These intermediary layers protect the structural integrity without requiring complete material replacement.
3Reliability
If multi-layer polymeric structure is implemented, then insulation and structural integrity are enhanced, but manufacturing process complexity increases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single extrusion lamination process. All three layers (insulative cellular non-aromatic polymeric material, polymeric lamination layer, and film layer) are co-extruded and bonded in one continuous operation, eliminating the need for separate lamination steps, adhesives, or post-assembly operations. This merging approach maintains structural integrity while simplifying the overall manufacturing workflow.
Solution Approach 2:
The patent implements self-service through self-adhering polymeric layers that bond to each other during extrusion without requiring external adhesives or additional bonding processes. The polymeric lamination layer and film layer are designed to adhere to the insulative cellular layer through inherent polymeric bonding mechanisms, allowing the structure to assemble itself during the extrusion process and reducing manufacturing complexity.
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 achieves enhanced insulation and structural integrity by maintaining a predetermined insulative characteristic while allowing localized plastic deformation, reducing condensation, and maintaining consistent thickness, even when filled with cold liquids.
Implementation Method 1
an insulative cellular non-aromatic polymeric material
Implementation Method 2
the cup gains minimal weight when filled with a cold liquid and subsequently exposed to a humid environment
Data Source
AI summary
A multi-layer sheet includes a polymeric foamed material, a polymeric-lamination layer, and a film. The polymer-lamination layer is extrusion laminated onto the polymeric foam.