Multi-Layer Insulating Sheet Without Adhesives for Recyclability
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Solution Overview
Problem
Current polymeric materials for insulating containers face challenges in achieving a balance between insulative properties, puncture resistance, recyclability, and microwavability, often compromising on one or more of these features.
Innovation Solution
A multi-layer sheet composed of an insulative cellular non-aromatic polymeric material, a polymeric-lamination layer, and a printed film layer, formed through an extrusion lamination process, which is adhesive-free and uses regrind to enhance properties like rigidity and recyclability, while maintaining insulative and puncture-resistant characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to couple the film layer and insulative cellular non-aromatic polymeric material, then bonding strength is improved, but recyclability and microwavability deteriorate
Solution Approach 1:
The patent removes adhesive from the multi-layer sheet construction entirely. Instead of using adhesive to bond the film layer to the insulative cellular non-aromatic polymeric material, the invention relies on the inherent bonding capabilities of the extrusion lamination process, which creates a mechanical and thermal bond without requiring separate adhesive materials. This extraction of adhesive enables both recyclability and microwavability while maintaining structural integrity.
Solution Approach 2:
The patent merges the bonding function with the extrusion lamination process itself. The polymeric-lamination layer serves dual purposes: it acts as both the bonding agent and the structural connection between layers. By combining the adhesive function into the extrusion process rather than using separate adhesive materials, the invention achieves strong bonding while maintaining material purity for recycling and microwave safety.
2Temperature
If multi-layer construction is used to improve insulative properties and puncture resistance, then thermal insulation and mechanical strength are improved, but material complexity increases
Solution Approach 1:
The patent applies local quality by assigning specific functions to specific layers. The insulative cellular non-aromatic polymeric material provides thermal insulation in the core layer, while the film layer provides puncture resistance and barrier properties on the outer surface. The polymeric-lamination layer provides structural bonding. Each layer is optimized for its specific function rather than using a single complex material for all purposes.
Solution Approach 2:
The patent uses composite materials by combining different polymeric layers with distinct properties. The multi-layer construction integrates an insulative cellular non-aromatic polymeric material (for thermal insulation), a film layer (for puncture resistance and barrier properties), and a polymeric-lamination layer (for bonding). This composite structure achieves superior overall performance while maintaining relative simplicity through the use of compatible polymeric materials that can be processed together.
3Strength
If regrind is used to enhance rigidity and recyclability, then structural strength and environmental sustainability are improved, but manufacturing process complexity increases
Solution Approach 1:
The patent implements a circular economy approach by incorporating regrind (recycled material) back into the production process. The insulative cellular non-aromatic polymeric material layer is formed using regrind, which recovers and reuses material from previous production runs. This eliminates waste, enhances recyclability, and maintains structural integrity through proper material formulation and processing controls.
Solution Approach 2:
The patent manages the complexity of using regrind by controlling key processing parameters during extrusion lamination. By optimizing temperature, pressure, and material composition ratios, the invention ensures that regrind-containing materials achieve consistent rigidity and bonding properties. This parameter control transforms a potentially complex recycling process into a manageable manufacturing operation with predictable outcomes.
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 improved insulative properties, enhanced puncture resistance, and recyclability, while avoiding the use of adhesives and ensuring microwavability, effectively addressing the limitations of existing materials.
Implementation Method 1
an insulative cellular non-aromatic polymeric material
Implementation Method 2
The multi-layer sheet may be formed by an extrusion lamination procedure that extrudes the polymer-lamination layer onto the insulative cellular non-aromatic polymeric material
Data Source
AI summary
A multi-layer sheet includes an insulative cellular non-aromatic polymeric material, a film, and a polymeric-lamination layer. The insulative cellular non-aromatic polymeric material may be formed from a polymeric formulation comprising a base resin blend and a physical nucleating agent.