Insulated Cup Multi-Layer Sheet for Graphics and Thermal Performance
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Solution Overview
Problem
Existing insulated containers fail to provide a combination of insulative performance, high-quality graphics, chemical resistance, puncture resistance, frangibility resistance, microwavability, and recyclability, often compromising on one or more of these features due to design limitations.
Innovation Solution
The development of an insulative cup made from a multi-layer sheet comprising a strip of insulative cellular non-aromatic polypropylene material with a skin layer featuring artwork, where the material allows for localized plastic deformation to achieve varying densities and enhanced properties, including a polypropylene base resin with high melt strength and cell-forming agents like carbon dioxide for reduced density and improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer insulative material is used, then manufacturing simplicity is maintained, but the ability to provide high-quality graphics and multiple functional properties (chemical resistance, puncture resistance, microwavability) deteriorates
Solution Approach 1:
The patent applies composite materials by combining multiple layers with distinct functions: an insulative cellular polymeric material layer for thermal insulation, a skin layer for graphics and chemical resistance, and an adhesive layer for bonding. This multi-layer composite structure enables the cup to simultaneously achieve high-quality graphics, chemical resistance, puncture resistance, and microwavability while maintaining manufacturing simplicity through integrated lamination processes.
2Temperature
If the insulative material density is reduced for better insulation, then thermal insulation performance improves, but structural strength and puncture resistance deteriorate
Solution Approach 1:
The patent resolves this contradiction by creating a composite structure where the insulative cellular polymeric material layer provides low density for thermal insulation, while the skin layer provides structural strength and puncture resistance. The adhesive layer bonds these layers together, creating a composite material system where each layer compensates for the weaknesses of the others, achieving both excellent insulation and structural integrity.
Solution Approach 2:
The patent applies local quality by assigning different material properties to different layers: the insulative layer has low density optimized for thermal insulation, while the skin layer has high strength optimized for structural integrity and puncture resistance. This localized optimization of material properties in different regions of the cup structure allows simultaneous achievement of both insulation performance and structural strength.
3Reliability
If a multi-layer structure with skin and adhesive layers is added, then graphics quality and chemical resistance improve, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent applies composite materials by integrating multiple functional layers (skin layer for graphics and chemical resistance, adhesive layer for bonding) into a unified multi-layer structure. While this increases structural complexity, the use of standard lamination and bonding processes keeps manufacturing complexity manageable, achieving a balance between enhanced functionality and manufacturability.
4Temperature
If conventional insulative materials are used, then basic insulation is provided, but the combination of microwavability, recyclability, and structural integrity cannot be achieved simultaneously
Solution Approach 1:
The patent applies parameter changes by selecting specific materials with optimized properties: the insulative cellular polymeric material is chosen for its microwavability (unlike traditional foam materials), recyclability, and insulation performance. The skin layer material parameters are selected to provide chemical resistance and graphics quality while maintaining compatibility with microwaving and recycling processes, enabling the cup to meet multiple conflicting requirements simultaneously.
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 provides a cup with superior insulative characteristics, high-quality graphics, chemical resistance, puncture resistance, microwavability, and recyclability, overcoming the limitations of previous designs by maintaining structural integrity and performance across various conditions.
Implementation Method 1
a strip of insulative cellular non-aromatic polymeric material
Implementation Method 2
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
Data Source
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.