Insulated container and method of making the same

Solution Overview

Problem

Current polymeric materials used for containers lack a combination of insulative properties, recyclability, puncture resistance, and microwavability, often compromising on one or more of these features due to design trade-offs.

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

VSEngineering Contradiction Analysis

1Temperature

If polymeric materials are designed for insulative properties, then thermal insulation is improved, but puncture resistance and structural strength deteriorate

Engineering Contradiction:

Improvethermal insulationVSAvoidpuncture resistance

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent applies composite materials by combining an insulative cellular non-aromatic polymeric material with a polymeric lamination layer. The cellular polymeric material provides thermal insulation through its cellular structure, while the polymeric lamination layer reinforces puncture resistance and structural strength. This composite structure resolves the contradiction by integrating materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating a multi-layer structure where different regions serve different functions. The insulative cellular polymeric material layer provides thermal insulation in the bulk, while the polymeric lamination layer provides structural reinforcement at the surface. This spatial differentiation of material properties allows simultaneous optimization of insulation and strength.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If polymeric materials are designed for recyclability, then environmental sustainability is improved, but insulative properties and performance deteriorate

Engineering Contradiction:

ImproverecyclabilityVSAvoidinsulative properties

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The patent applies homogeneity by using a non-aromatic polymeric material that is substantially free of aromatic compounds and adhesives throughout the structure. This homogeneous composition enables recyclability while the cellular structure maintains insulative properties. The uniform material composition allows for effective recycling processes without compromising insulative performance in recycled applications.

Inventive Principle:

Principle #33Homogeneity

3Use of energy by moving object

If polymeric materials are designed for microwavability, then heating capability is improved, but insulative properties and thermal retention deteriorate

Engineering Contradiction:

ImprovemicrowavabilityVSAvoidthermal retention

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The patent applies local quality by creating a multi-layer structure where different regions serve different functions. The insulative cellular polymeric material layer provides thermal insulation in the bulk, while the polymeric lamination layer provides structural reinforcement at the surface. This spatial differentiation of material properties allows simultaneous optimization of insulation and strength.

Inventive Principle:

Principle #3Local quality

4Stability of the object's composition

If polymeric materials are designed for rigidity, then structural stability is improved, but deformability and impact resistance deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoidimpact resistance

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The patent applies composite materials by combining an insulative cellular non-aromatic polymeric material with a polymeric lamination layer. The cellular polymeric material provides thermal insulation through its cellular structure, while the polymeric lamination layer reinforces puncture resistance and structural strength. This composite structure resolves the contradiction by integrating materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

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 chemical resistance, thus overcoming the limitations of existing materials.

Implementation Method 1

insulative cellular non-aromatic polymeric material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

insulative cellular non-aromatic polymeric material

Methodology Applied

Scientific EffectCellular structure: Foam

Data Source

PatentUS11091311B2Insulated container and method of making the same

Publication Date: 2021.08.17 BERRY GLOBAL INC

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.