Insulated Polypropylene Cup Structure for Printed Artwork
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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, nucleating agents, and blowing agents like carbon dioxide, which allows for localized plastic deformation and direct printing of high-resolution graphics, while maintaining insulative characteristics and being recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional insulated container materials are used, then insulative performance is achieved, but recyclability and resistance to leaching undesirable substances deteriorate
Solution Approach 1:
The patent changes the material parameters by using food-grade polypropylene with specific molecular weight distribution (bimodal distribution with first peak at 5,000-15,000 and second peak at 50,000-150,000) and controlling cellular structure parameters (cell size 0.01-0.05 inches, density 0.02-0.08 g/cm³) to achieve both insulation performance and recyclability. This parameter optimization resolves the contradiction between insulative performance and material safety/recyclability.
Solution Approach 2:
The patent creates a composite structure combining polypropylene base resin with nucleating agents and blowing agents to form a cellular foam material. This composite material simultaneously provides thermal insulation properties while maintaining food-grade safety and recyclability, resolving the contradiction between insulative performance and reliability.
2Illumination intensity
If high-quality graphics are applied to insulated containers, then visual appeal is improved, but manufacturing complexity and material loss increase
Solution Approach 1:
The patent incorporates colorants and pigments into the polypropylene resin formulation before extrusion, allowing graphics and colors to be built into the material itself during the extrusion process. This preliminary incorporation of visual elements eliminates the need for separate printing or coating steps, reducing manufacturing complexity while maintaining high graphics quality.
Solution Approach 2:
The patent merges the graphics application function with the material extrusion process by incorporating colorants and design elements directly into the polypropylene compound before forming the container. This consolidation of functions reduces the number of manufacturing steps and minimizes material handling, thereby reducing both complexity and material loss.
3Strength
If the container structure is made more robust for puncture and frangibility resistance, then strength is improved, but weight and material consumption increase
Solution Approach 1:
The patent utilizes a cellular foam structure with controlled porosity (density 0.02-0.08 g/cm³) where the closed-cell configuration provides both insulation and structural strength. The cellular structure distributes stress throughout the material, providing puncture and frangibility resistance without requiring solid, heavy material, thus maintaining low weight.
Solution Approach 2:
The patent applies localized reinforcement strategies by controlling the cellular structure and wall thickness distribution in specific regions of the container. The extrusion process allows for varying wall thickness and cell density in different areas, providing enhanced strength where needed while maintaining overall lightweight construction.
4Adaptability or versatility
If the container is designed for microwavability, then adaptability is improved, but insulative performance may deteriorate due to material composition
Solution Approach 1:
The patent selects polypropylene as the base resin specifically because it is microwave-safe and has appropriate dielectric properties for microwave heating. The molecular weight distribution and additive package are optimized to ensure the material can withstand microwave temperatures while maintaining its insulative cellular structure, thus achieving both microwavability and insulation performance.
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 effective insulation, recyclability, resistance to punctures and frangibility, and safe 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
Implementation Method 2
insulative cellular non-aromatic polymeric material
Implementation Method 3
cell-forming agents including primary and secondary nucleating agents
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.