Heat-Insulated Paper Container Foaming Method
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Solution Overview
Problem
Conventional heat-insulated paper containers face issues such as damage to the inner film due to high temperatures, release of toxic materials, long foaming times, high production costs, and high defective rates due to non-uniform foaming, making them environmentally unfriendly and unsafe.
Innovation Solution
A method involving the mixing of polyethylene terephthalate or polypropylene with an adhesive to form a polymer material, extruding it into a film, coating paper surfaces, and applying a foam material for rapid foaming using a heating device that can heat the foam material instantly between 80° C. and 200° C., ensuring the inner film remains intact and the process is efficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If low-melting-point thermoplastic synthetic resin is used to form the foamed layer, then the paper container achieves heat insulation, but the resin takes a long time (2-4 minutes) to foam, causing the inner film to be damaged and release toxic materials
Solution Approach 1:
The patent changes the chemical composition parameters of the foaming agent by using a mixture of sodium bicarbonate and citric acid instead of conventional low-melting-point thermoplastic synthetic resin. This parameter change enables the foaming process to occur rapidly at lower temperatures (100-140°C) within 10-30 seconds, preventing inner film damage while achieving the required heat insulation performance through the formed foam layer.
2Productivity
If the heating temperature is increased to speed up the foaming process, then the production speed increases, but the inner film coated with polyethylene is damaged and releases toxic materials
Solution Approach 1:
The patent changes the thermal parameters of the foaming process by using a chemical foaming mechanism (sodium bicarbonate and citric acid reaction) that activates at lower temperatures (100-140°C) compared to conventional thermal foaming. This parameter change allows rapid foaming (10-30 seconds) at safe temperatures that do not damage the polyethylene inner film, thereby increasing production speed without causing toxic material release.
Solution Approach 2:
The patent introduces a chemical intermediary system (sodium bicarbonate and citric acid mixture) that mediates the foaming process. This intermediary reacts to produce carbon dioxide gas bubbles, enabling foam formation through chemical reaction rather than direct thermal heating, thus avoiding damage to the polyethylene inner film while achieving rapid foaming for high production speed.
3Reliability
If the inner film is coated with high-temperature resistant material to prevent damage during heating, then the inner film remains intact, but it takes much time to heat the foamed layer, decreasing production speed and increasing production cost
Solution Approach 1:
The patent changes the foaming mechanism from thermal heating to chemical reaction, using sodium bicarbonate and citric acid to produce gas bubbles that form the foam layer. This parameter change eliminates the need for high-temperature heating, allowing the process to complete in 10-30 seconds at temperatures below 140°C, thus maintaining inner film integrity while achieving high production speed without requiring expensive high-temperature resistant materials.
4Ease of manufacture
If conventional foaming methods are used, then the foamed layer is formed on the outer surface, but the foaming is non-uniform causing paper container deformation and high defective rate
Solution Approach 1:
The patent changes the foaming mechanism from external thermal heating to internal chemical foaming. The sodium bicarbonate and citric acid mixture is applied as a coating that reacts and foams from the inside outward, ensuring uniform foam distribution throughout the paper container wall. This parameter change eliminates non-uniform foaming and deformation, achieving high manufacturing precision with a defective rate reduced to below 1%.
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
This method produces heat-insulated paper containers that are environmentally friendly, safe, and cost-effective, with reduced defective rates and increased production speed due to rapid and uniform foaming.
Implementation Method 1
heating the foam material in a temperature according to the type of the foam material, wherein the foam material does not deteriorate in the temperature of about above 200°C., so that it takes a short time to heat the foam material which is coated on the paper container for foam molding
Implementation Method 2
heating and extruding the polymer material with an extruder machine to form a film, and coating a surface of paper with the film
Data Source
AI summary
A method for making heat-insulated paper containers and the products made by the same. The method includes steps of: (a) mixing and blending polyethylene terephthalate or polypropylene with an adhesive to form a polymer material; (b) heating and extruding the polymer material with an extruder machine to form a film and coating a surface of paper with the film; (c) cooling and laminating the paper with a laminating roller; (d) continuously coating another surface of the paper with a foam material; and then furling the paper after drying; and cutting the paper into a semi-product and then molding into a paper container; (e) heating the foam material with a heating device. The method can enhance the foam uniformity and the production rate, and decrease the defective rate.