Laminate Sheet Container for Recyclable Structural Rigidity
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Solution Overview
Problem
Existing sheet material containers face challenges in improving recyclability while maintaining their functional properties, particularly in reducing waste and environmental impact.
Innovation Solution
The development of a sheet material container with a specific laminate structure, where the tensile modulus of elasticity of the base material films is set to at least 1 GPa, and the total thickness ratio of the base material films to the attaching layer is optimized to enhance recyclability and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the thickness of the flexible material is reduced to reduce waste, then the environmental impact is reduced, but the structural integrity and rigidity of the container deteriorates
Solution Approach 1:
The patent employs a laminate structure comprising multiple base material films (first base material film and second base material film) combined with an attaching layer. This composite construction allows each layer to contribute specific properties: the base material films provide structural strength and rigidity, while the thin attaching layer provides adhesion. The synergistic combination enables the container to maintain structural integrity even when individual layers are made thinner, thus reducing overall material usage and waste without compromising strength.
Solution Approach 2:
The patent utilizes thin film structures for the base material films and attaching layer. By optimizing the thickness of each film layer and combining them in a laminate configuration, the container achieves sufficient mechanical strength despite the thin overall structure. This approach reduces material consumption and waste while maintaining the necessary structural properties for container functionality.
2Loss of substance
If a laminate structure with attaching layers is used to reduce material thickness, then waste is reduced, but the complexity of the structure increases
Solution Approach 1:
The patent extracts and separates the functional requirements into distinct layers: the base material films handle structural support and rigidity requirements, while the attaching layer specifically handles the adhesion function. This separation of functions allows each layer to be optimized independently for its specific purpose, reducing the need for thicker, more complex single-layer structures that would need to simultaneously provide both structural strength and adhesion.
Solution Approach 2:
By combining different material types in a laminate structure, the patent achieves complex functionality through a systematic arrangement of simpler components. The base material films and attaching layer are combined in a structured manner that provides both structural integrity and adhesion, reducing overall material usage while maintaining functionality. The composite approach allows for optimized material selection and thickness for each specific function.
3Strength
If the tensile modulus of elasticity of base material films is increased to maintain structural rigidity, then the structural rigidity is improved, but the difficulty of recycling increases
Solution Approach 1:
The patent segments the container structure into separable layers: base material films and an attaching layer. This segmentation allows the layers to be separated for recycling purposes. The base material films can be recovered and recycled independently from the attaching layer. By designing the laminate structure with separable interfaces, the patent enables recycling processes to isolate and process different material types separately, thereby improving overall recyclability while maintaining structural rigidity through the optimized base material film properties.
Solution Approach 2:
The patent facilitates the recovery and recycling of base material films by designing a laminate structure where these films can be separated from the attaching layer. The structural rigidity is maintained in the recoverable base material films, which can then be collected and recycled. This approach enables the discarding of minimal material (the attaching layer) while recovering and reusing the majority of the material (base material films) that provides the structural function.
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
This solution improves the recyclability of the sheet material container while maintaining its structural rigidity and functional properties, ultimately reducing environmental waste and loads.
Implementation Method 1
a first base material film (121a), a second base material film (122a), and an attaching layer (121b) attaching the first base material film (121a) and the second base material film (122a) to each other
Data Source
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AI summary
A sheet material container includes a container body that surrounds a containing portion for accommodating a content. The container body is formed of a container body-forming sheet member formed by layering a plurality of base material films. The container body-forming sheet member includes the plurality of base material films, an attaching layer by which the base material films are attached to each other, and a filler enclosed portion that is formed between the plurality of base material films and into which a filler is to be filled. The plurality of base material films are made from the same type of resins.