Insulated Cup Wrapper with Corrugated Insert
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Solution Overview
Problem
Existing insulated cups and containers face challenges such as poor thermal insulation, environmental unfriendliness, high production costs, and difficulties in printing and assembly, particularly with materials like EPS and multi-layered paper cups.
Innovation Solution
A thermally insulated container design featuring a single-walled paper or plastic inner cup wrapped with an insulating outer wrapper comprising a paper base sheet and a corrugated insert, which is glued in a centered position to form a two-layered wrapper, allowing for efficient assembly and printing without the need for folding or expensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If EPS cups are used, then thermal insulation is improved, but environmental friendliness deteriorates
Solution Approach 1:
The invention uses a composite structure combining an inner cup (paper or plastic) with an outer insulating wrapper made of different materials (foam, air gap, or insulating material), creating a multi-material system that provides thermal insulation without using EPS, thus resolving the contradiction between insulation performance and environmental friendliness
2Temperature
If multi-layered paper cups with corrugated sheets are used, then thermal insulation is improved, but manufacturing cost deteriorates
Solution Approach 1:
The invention divides the insulating structure into separate components: an inner cup and an outer wrapper that can be manufactured independently and then assembled. This segmentation eliminates the need for expensive lamination processes required by multi-layered paper cups, reducing manufacturing cost while maintaining insulation performance
3Temperature
If multi-layered paper cups with corrugated sheets are used, then thermal insulation is improved, but device complexity deteriorates
Solution Approach 1:
By separating the insulating function into a distinct outer wrapper component rather than integrating it into a complex multi-layered paper structure, the invention reduces overall structural complexity while achieving the same thermal insulation effect through a simpler, modular design
4Temperature
If cup sleeves are used, then thermal insulation is improved, but assembly speed deteriorates
Solution Approach 1:
The invention merges the cup and insulating wrapper into a single pre-assembled unit where the wrapper is integrated onto the inner cup during manufacturing. This eliminates the need for separate assembly of cup sleeves at the point of service, significantly improving assembly speed while maintaining insulation performance
5Duration of action of stationary object
If plastic cups are used, then shelf life is improved, but thermal insulation deteriorates
Solution Approach 1:
The invention creates a composite structure combining a plastic inner cup (which provides barrier properties for extended shelf life) with an outer insulating wrapper (which provides thermal insulation). This composite design simultaneously achieves both shelf life extension and thermal insulation without the trade-off present in single-material plastic cups
6Reliability
If plastic cups are used, then moisture barrier is improved, but thermal insulation deteriorates
Solution Approach 1:
The invention uses a composite structure where the plastic inner cup provides excellent moisture and oxygen barrier properties, while the outer insulating wrapper provides thermal insulation. This composite design achieves both moisture barrier reliability and thermal insulation performance simultaneously, resolving the contradiction between these two properties in single-material plastic cups
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 improved thermal insulation, rigidity, and cost-effectiveness, extending the shelf life of contents, making the container microwavable, and allowing for easier printing and assembly, while reducing material costs and environmental impact.
Implementation Method 1
an insulating outer wrapper comprising a paper base sheet or outer sidewall blank, optionally printed on one side, and a corrugated paper insert
Data Source
AI summary
A thermally insulated cup is formed from a single-walled paper or plastic inner cup and an insulating outer wrapper. The insulating outer wrapper comprises a paper base sheet or outer sidewall blank, optionally printed on one side, and a corrugated paper or foamed plastic insulating insert. The insulating insert is similar in shape to the outer sidewall blank but smaller in size. The insert is glued in a centered position to the non-printed side of the sidewall blank to form a two-layered insulating wrapper. Less than 20% of the area of the insert is glued to the base sheet. Specifically, no glue is applied to the area adjacent to the cut side edges of the insert, and as such these edges are not attached to the base sheet. The wrapper is then wrapped around the single walled inner cup. The side edges of the base sheet of the wrapper overlap and are sealed directly together to form a side seam. The side seam is itself adhesively secured to the side wall of the inner cup. The side edges of the insert do not come between the seal between the side seam of the base sheet and the inner cup. The wrapper can also be adhered to the inner cup by one or more beads of cold glue (paste adhesive) or a thin layer of polyethylene (or similar heat sealing material) can be pre-applied to the inside cut edges of the base sheet. This is then heat-activated immediately prior to wrapping the wrapper around the inner cup, and pressing the overlapping side seam to the sidewall of the inner cup to simultaneously glue the side seam together, and to glue the insulating wrapper to the side wall of the cup.