Composite thermoformed tableware and preparation method thereof
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Solution Overview
Problem
The production process of molded fiber pulp tableware is complex and costly, and existing plastic tableware is non-biodegradable and expensive, with composite thermoformed tableware solutions lacking in strength and environmental friendliness.
Innovation Solution
A method involving preheating, compositing, and thermoforming of multilayer materials, including paper, plastic, and inorganic layers, with an adhesive and grease-proof layer, to create a strong and environmentally friendly composite tableware structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molded fiber pulp tableware is produced using traditional vacuum suction and high temperature drying processes, then the tableware can be formed, but the production process becomes complicated and manufacturing cost increases
Solution Approach 1:
The forming process is divided into distinct stages: preheating the pulp slurry to 35-150°C to activate adhesive properties, then applying vacuum suction to transfer to mold, followed by thermal pressing at 80-150°C and 0.05-0.5MPa. This segmentation allows each stage to be optimized independently, simplifying the overall process control
Solution Approach 2:
The patent changes key process parameters: preheating temperature (35-150°C), vacuum pressure (0.05-0.5MPa), and thermal pressing conditions (80-150°C, 0.05-0.5MPa). These parameter optimizations enable the process to achieve good forming results with simpler equipment requirements compared to traditional high-temperature vacuum drying
2Strength
If the thickness and strength of molded fiber pulp tableware are increased to meet performance requirements, then the tableware can hold food better, but the production cost increases and the process becomes more complex
Solution Approach 1:
The patent uses composite material structure with multiple layers of different materials (paper, plastic, inorganic layers) bonded together. This allows the tableware to achieve high strength and thickness requirements while maintaining manufacturing simplicity, as each layer contributes specific properties and the bonding process is integrated into the forming cycle
Solution Approach 2:
The patent applies adhesive coating to the pulp slurry before forming, and preheats the material to activate adhesive properties. This preliminary action ensures strong bonding between layers during the forming process itself, rather than requiring separate bonding steps, thus achieving high strength without increasing process complexity
3Reliability
If traditional plastic tableware is used to ensure durability and food contact safety, then the tableware performance is good, but the environmental friendliness deteriorates due to non-biodegradability
Solution Approach 1:
The patent creates composite tableware using biodegradable materials including plant fiber pulp, starch, and natural adhesives. The composite structure combines paper, plastic, and inorganic layers to achieve plastic-like durability and food contact safety while maintaining biodegradability, thus resolving the contradiction between performance and environmental friendliness
Solution Approach 2:
The patent optimizes the composition ratios and processing parameters of biodegradable materials to achieve physical and mechanical properties comparable to traditional plastics. By controlling moisture content, adhesive composition, and thermal pressing conditions, the tableware achieves sufficient strength and durability for food service while remaining environmentally friendly
4Object-affected harmful factors
If degradable plastic tableware such as PLA is used to improve environmental friendliness, then the biodegradability increases, but the production cost increases and market utilization rate remains low
Solution Approach 1:
The patent segments the material composition into multiple layers with different functions: outer protective layers, inner food-contact layers, and bonding layers. This allows selective use of biodegradable materials only where necessary, reducing overall material cost while maintaining environmental friendliness and performance
Solution Approach 2:
The patent uses natural adhesives and coating agents as intermediaries to bond biodegradable material layers. These intermediaries enable the use of lower-cost biodegradable materials while achieving the same structural integrity as expensive single-material PLA tableware, thus reducing production cost while maintaining environmental benefits
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 method simplifies the production process, enhances the strength and thickness of tableware, and ensures environmental friendliness by using biodegradable materials, while providing effective water and grease resistance without fluorine or PFAS ingredients.
Implementation Method 1
an adhesive is coated between two adjacent forming materials
Implementation Method 2
heating reduces the moisture of the composite material so as to improve the liquid absorption of the composite material
Implementation Method 3
providing effective water and grease resistance
Data Source
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AI summary
Composite thermoformed tableware and preparation method thereof are provided. The preparation method comprises a preheating step, a compositing step and a thermoforming step in sequence. The preheating step comprises heating multilayer forming materials at a temperature of 35℃ to 150℃, and the forming materials comprise one or at least two of paper, plastic and inorganic layer. The compositing step comprises stacking the preheated forming materials to form a composite material. The thermoforming step comprises heat-pressing the composite material at a temperature of 80℃ to 150℃ and a pressure of 0.05MPa to 0.5MPa to form a three-dimensional body. The tableware is thermoformed by multiple layers of the same material or different materials, so that the thickness and strength of the tableware are higher, the process is simple without complex and complicated procedures, and the production cost is better controlled.