Laminated Paperboard Pressware Container Rigidity

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Solution Overview

Problem

Traditional cutting boards, trays, and containers are prone to food contamination due to the transfer of bacteria, viruses, and food particles, while disposable alternatives like plastic films and paper products lack rigidity and are difficult to recycle.

Innovation Solution

The development of disposable pressware paperboard products with a laminated structure comprising multiple layers of paperboard and a waterproof coating between them, providing both wet and dry strength while being cost-effective and environmentally friendly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If disposable cutting sheets are made from thin plastic films to eliminate food contamination, then hygiene is improved, but rigidity and puncture resistance deteriorate

Engineering Contradiction:

Improvefood contaminationVSAvoidrigidity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent uses a laminated structure combining multiple paperboard layers with a waterproof coating layer. This composite material provides both the hygiene of disposable materials and the rigidity needed to support heavy food items, eliminating the weakness of thin plastic films while maintaining disposability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the physical parameters of paperboard by applying waterproof coatings and using specific basis weights (80-350 lbs/3000 ft²) and calipers (10-30 mils). These parameter changes transform ordinary paper into a material that is both water-resistant and structurally rigid, suitable for disposable food service applications.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If paper products are used to reduce food contamination, then hygiene is improved, but water resistance and structural integrity deteriorate

Engineering Contradiction:

Improvefood contaminationVSAvoidwater resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent creates a composite structure with a waterproof coating layer (polymer, plastic, or wax) applied to paperboard layers. This composite provides both the hygiene benefits of disposable paper products and the water resistance needed to maintain structural integrity when contacting food liquids.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The waterproof coating layer acts as a protective thin film that prevents water penetration while maintaining the flexibility and disposability of the paperboard structure. This thin film barrier provides reliable water resistance without compromising the overall product flexibility.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If EPS foam is used for disposable containers to achieve strength and rigidity, then structural integrity is improved, but recyclability and environmental friendliness deteriorate

Engineering Contradiction:

Improvestructural integrityVSAvoidrecyclability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent uses paperboard with specific parameters (basis weight 80-350 lbs/3000 ft², caliper 10-30 mils) that can be engineered to achieve structural integrity comparable to EPS foam. These parameter changes allow paperboard to replace foam while maintaining strength and enabling recyclability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a disposable paperboard container that is economically viable and environmentally friendly. By optimizing paperboard parameters and using waterproof coatings, the product achieves single-use functionality with structural integrity, replacing non-recyclable EPS foam with recyclable paper-based materials.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Area of stationary object

If paper trays are made larger to provide sufficient surface area, then usability is improved, but rigidity and ability to support heavy food items deteriorate

Engineering Contradiction:

Improvesurface areaVSAvoidrigidity

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The patent uses laminated paperboard structures with waterproof coatings that provide enhanced strength-to-area ratio. This composite material allows large surface areas (suitable for trays) while maintaining the rigidity needed to support heavy food items, overcoming the limitation of conventional paper trays.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent specifies paperboard parameters (basis weight 80-350 lbs/3000 ft², caliper 10-30 mils) that can be adjusted to achieve optimal rigidity for large-area trays. These parameter changes enable the production of large, usable trays that maintain structural integrity under heavy loads.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12263985B2Press-formed disposable container made from a laminated paperboard structure

Publication Date: 2025.04.01 GPCP IP HOLDINGS LLC

AI summary

A compostable disposable container made from a paperboard laminate. The paperboard laminate has a first paperboard layer, a second paperboard layer, and a waterproof coating disposed between the first and second paperboard layers. One or more additional surface coatings that are water resistant can be added to outer surfaces of the laminate. The laminate structure is able to be press-formed at higher forming temperatures, resulting in a stronger, more rigid container.