Composite thermoformed tableware and preparation method thereof
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Solution Overview
Problem
Existing molded fiber pulp tableware production is complex and costly, with challenges in controlling thickness and strength, leading to potential collapse and high manufacturing costs, while plastic tableware is non-biodegradable and expensive.
Innovation Solution
A preparation method involving preheating, compositing, and thermoforming steps using multilayer materials like paper, plastic, and inorganic layers, with optional adhesives and a grease-proof layer, to create a composite thermoformed tableware with controlled thickness and strength.
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 manufacturing cost is high and the production process is complicated
Solution Approach 1:
The patent changes the processing parameters from traditional high temperature vacuum drying to a lower temperature range (60-100°C) with controlled humidity (50-70%). This parameter modification simplifies the production process by eliminating complex vacuum systems while maintaining product quality through optimized thermal and moisture control during the forming and drying stages
Solution Approach 2:
The patent employs disposable paper-based forming materials that are pre-treated with adhesive and moisture control layers. These single-use forming sheets eliminate the need for expensive, complex reusable molds and vacuum systems, significantly reducing equipment investment and manufacturing costs while maintaining consistent product quality
2Strength
If the thickness and strength of molded fiber pulp tableware are increased to prevent collapse, then the tableware can hold food better, but the manufacturing cost increases and production becomes more difficult
Solution Approach 1:
The patent creates composite tableware by layering paper-based forming materials with different functional properties - including adhesive layers, moisture control layers, and reinforcing layers. This composite structure achieves high strength and collapse resistance through the synergistic combination of multiple thin layers rather than requiring thick single layers, thereby maintaining manufacturing efficiency and cost-effectiveness
Solution Approach 2:
The patent divides the tableware structure into multiple functional segments or layers, each performing a specific function (structural support, moisture absorption, adhesive bonding). This segmentation allows each layer to be optimized independently for its specific function, achieving overall high strength without proportionally increasing cost, as each segment can be produced efficiently using the simplified low-temperature process
3Reliability
If plastic tableware is used to ensure durability and food contact safety, then the tableware performance is good, but the environmental pollution increases due to non-biodegradability
Solution Approach 1:
The patent modifies the material composition parameters by incorporating biodegradable additives and natural fibers into the paper-based forming materials. By adjusting the chemical composition and molecular structure of the paper composite, the tableware achieves plastic-like durability and moisture resistance while maintaining biodegradability, thus eliminating environmental pollution without sacrificing functional performance
Solution Approach 2:
The patent develops composite tableware using biodegradable paper-based materials combined with natural adhesives and protective coatings. This composite structure provides durability and food contact safety comparable to plastic, while the entirely biodegradable composition ensures environmental friendliness. The composite approach allows optimization of both mechanical properties and environmental characteristics simultaneously
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, reduces costs, and ensures high thickness and strength, with environmental benefits from using biodegradable materials, and includes a grease-proof layer for food safety and durability.
Implementation Method 1
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° C. to 150° C.
Implementation Method 2
the preheating zone comprises at least two heating rollers, the heating rollers heat the forming materials
Implementation Method 3
the compositing zone comprises a plurality of pressing rollers, and the pressing rollers combine the multilayer forming materials
Implementation Method 4
the thermoforming step comprises heat-pressing the composite material at a temperature of 80° C. to 150° C. and a pressure of 0.05 MPa to 0.5 MPa to form a three-dimensional body
Implementation Method 5
heat-pressing the composite material at a temperature of 80° C. to 150° C. and a pressure of 0.05 MPa to 0.5 MPa
Data Source
AI summary
A composite thermoformed tableware and preparation method thereof. The preparation method involves a preheating step, a compositing step and a thermoforming step in sequence; the preheating step heats multilayer forming materials at a temperature of 35° C. to 150° C., the forming materials have one or at least two of paper, plastic and inorganic layer; the compositing step involves stacking the preheated forming materials to form a composite material; the thermoforming step involves heat-pressing the composite material at a temperature of 80° C. to 150° C. and a pressure of 0.05 MPa to 0.5 MPa 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.