Multi-Layer Cellular Polymeric Cup for Insulation and Recyclability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current polymeric materials used for containers lack a combination of insulative properties, recyclability, puncture resistance, and microwavability, often sacrificing one feature for another, such as being insulated but not recyclable or puncture-resistant.
Innovation Solution
A multi-layer sheet comprising an insulative cellular non-aromatic polymeric material, a polymeric-lamination layer, and a printed film layer, where the polymeric-lamination layer is formed from a blend of polypropylene and cell-forming agents, and regrind, which is free of adhesives, to create a cup with enhanced rigidity and resistance to deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional polymeric materials are used for containers, then manufacturing is simple and cost-effective, but insulative properties are insufficient
Solution Approach 1:
The patent uses a composite material structure consisting of a thermoplastic polymeric material with dispersed cell-forming agents. The cells create an insulative cellular structure within the polymeric matrix, combining the simplicity of thermoplastic processing with the insulative properties of cellular structures. This resolves the contradiction by achieving good insulative properties through a relatively simple composite material system.
2Temperature
If aromatic polymeric materials are used, then insulative properties are improved, but recyclability and microwavability are compromised
Solution Approach 1:
The patent changes the chemical composition parameters by using non-aromatic thermoplastic polymeric materials instead of aromatic materials. This parameter change maintains insulative properties through the cellular structure while improving recyclability and microwavability by selecting thermoplastic materials that are environmentally acceptable and suitable for microwave heating. The cell structure provides insulation without requiring aromatic chemistry.
3Quantity of substance
If thin-walled containers are used, then material usage is reduced, but puncture resistance and deformation resistance are insufficient
Solution Approach 1:
The patent employs a cellular (porous) structure within the polymeric material where cell-forming agents create dispersed cells during processing. This cellular structure provides mechanical strength and resistance to puncture and deformation while using less material than solid walls. The cells act as structural reinforcement, allowing thin-walled construction with adequate strength.
4Strength
If adhesive layers are used to bond container layers, then bonding strength is improved, but recyclability and food safety are compromised
Solution Approach 1:
The patent extracts and eliminates adhesive layers from the container structure. Instead of using separate adhesive layers to bond components, the invention uses a unitary thermoplastic polymeric material that is formed and shaped during processing. This eliminates the need for adhesives, thereby maintaining bonding integrity through the polymeric material itself while preserving recyclability and food safety.
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 improved insulative properties, recyclability, and resistance to puncture and deformation, while maintaining high-quality graphics and being suitable for both hot and cold contents, and capable of withstanding dishwasher cycles.
Implementation Method 1
insulative cellular non-aromatic polymeric material
Implementation Method 2
insulative cellular non-aromatic polymeric material
Data Source
AI summary
An insulative cup is formed of a multi-layer sheet. The multi-layer sheet comprises an insulative cellular non-aromatic polymeric material, a film layer, and a polymeric lamination layer. The insulative cellular non-aromatic polymeric material is formed from a formulation comprising a base resin blend and a physical nucleating agent.