Thermoformable Paper Food Packaging with Dimensional Stability
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Solution Overview
Problem
Conventional food packaging using metal foils, such as aluminum, poses environmental concerns due to high energy requirements for production and recycling, and can cause heat-induced melting of food surfaces during sealing, while paper-based packaging lacks dimensional stability for contour-forming applications.
Innovation Solution
Development of food packaging using thermoformable paper material with hydrophobized cellulose, which allows for the creation of dimensionally stable partial shells that can be shaped to closely fit food products, including those with complex geometries, using a process that involves heating and/or moistening to achieve a strong, contour-forming attachment without thermal conductivity issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If metal foil material is used for partial shells, then dimensional stability and contour-forming capability are achieved, but environmental sustainability deteriorates due to high energy requirements for production and recycling
Solution Approach 1:
The patent applies parameter changes by treating paper material with hydrophobizing agents and applying specific surface treatments to enable it to achieve dimensional stability comparable to metal foils. The paper is subjected to controlled moisture and heat treatment during forming to stabilize its dimensions while maintaining environmental benefits
Solution Approach 2:
The patent uses composite materials by combining paper with hydrophobizing coatings and potentially other functional layers to create a multi-layer structure that achieves both dimensional stability and environmental sustainability. This composite approach allows the paper to perform previously metal-exclusive functions
2Shape
If metal foil material is used for partial shells, then contour-forming capability is improved, but harmful thermal effects occur during sealing that can melt food surfaces
Solution Approach 1:
The patent employs disposable paper-based partial shells that are designed for single use, eliminating the need for thermal sealing processes that cause harmful heat effects. The disposable nature allows for alternative closing methods that do not involve high-temperature contact with food surfaces
Solution Approach 2:
The patent changes the physical parameters of paper material through hydrophobization and thermal conditioning to achieve sufficient dimensional stability for contour-forming applications without requiring the high thermal conductivity properties of metal, thereby avoiding heat transfer to food during sealing operations
3Use of energy by stationary object
If paper material is used for partial shells, then environmental sustainability is improved, but dimensional stability deteriorates preventing effective contour-forming
Solution Approach 1:
The patent fundamentally changes the parameters of paper material by applying hydrophobizing treatments and controlling moisture content to transform it from a dimensionally unstable material into one that maintains stable dimensions during and after the forming process, enabling effective contour-forming applications
Solution Approach 2:
The patent applies preliminary actions by pre-treating the paper material with hydrophobizing agents and conditioning it to appropriate moisture levels before the forming process, ensuring that the material achieves the necessary dimensional stability in advance to successfully contour-form around food products
4Shape
If paper material is strongly bent for contour-forming applications, then contour-mapping capability is improved, but material integrity deteriorates due to tearing
Solution Approach 1:
The patent changes the physical parameters of paper by controlling its moisture content and applying hydrophobizing treatments to increase flexibility and tear resistance, enabling the material to be strongly bent for contour-forming without compromising structural integrity
Solution Approach 2:
The patent employs composite material structures that combine paper with flexible coatings or interlayers that enhance tear resistance while maintaining the ability to be strongly bent for contour-mapping applications, preventing material failure during forming
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 sustainable, dimensionally stable paper-based packaging that maintains food product contours, reduces heat transfer during sealing, and ensures a snug fit without material tearing, enabling efficient packaging of various food shapes and sizes while minimizing environmental impact.
Implementation Method 1
The paper material is hydrophobized in a known manner, for example, by treatment with a hydrophobizing agent
Implementation Method 2
the paper material or the partial shell (n) has been treated with moisture immediately before the forming
Implementation Method 3
or has been heated or heated and/or moistened before and/or during the forming
Data Source
Figure 1a~1b
Figure 1c~2
Figure 3
AI summary
The present invention relates to a food packaging with at least two partial shells (13, 13', 113, 113', 413, 413', 513, 513') which are connected to each other via opposing and at least partially abutting flanges (14, 14', 114, 114', 414, 414', 514, 514') and enclose a food product (100), wherein the partial shells (13, 13', 113, 113', 413, 413', 513, 513') conform to the shape of the food product (100). To provide environmentally friendly packaging with low thermal conductivity, at least one of the at least two partial shells (13, 13', 113, 113', 413, 413', 513, 513') is formed from a section of paper material.