Paperboard-Plastic Container Rim Structure With Less Plastic

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Solution Overview

Problem

Existing containers with a paperboard and plastic foil combination are costly due to thick plastic layers for strength, and the layers are difficult to separate, complicating recycling.

Innovation Solution

A container design with a reduced thickness plastic foil layer and a rolled-up paperboard rim portion, allowing for a strong and stiff upper rim while minimizing plastic use, and facilitating easy separation of layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a thick plastic foil layer is used to provide strength and stiffness to the container rim, then the structural integrity is improved, but the plastic content and cost increase

Engineering Contradiction:

Improverim strengthVSAvoidplastic content

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The container structure is segmented into distinct functional layers: a thin plastic foil layer (50-200 µm) for barrier properties and a thick paperboard outer layer with rolled-up rim portions for structural strength. This segmentation allows each material to contribute its optimal properties without requiring excessive plastic content.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining plastic foil and paperboard materials. The outer paperboard layer forms rolled-up rim portions that provide mechanical strength, while the inner thin plastic foil layer provides barrier functionality. This composite approach replaces the conventional single-thick-plastic-layer design, reducing plastic content by up to 70% while maintaining rim strength.

Inventive Principle:

Principle #40Composite materials

2Strength

If a thick plastic foil layer is used to ensure structural integrity, then the container strength is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvecontainer strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the thickness parameter of the plastic foil layer from conventional thick layers to a thin layer (50-200 µm). This parameter change is compensated by introducing rolled-up paperboard rim portions that provide the necessary structural support, thereby reducing material costs while maintaining container strength.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If a thin plastic foil layer is used to reduce plastic content, then the plastic content is reduced, but the structural integrity of the rim deteriorates

Engineering Contradiction:

Improveplastic contentVSAvoidrim strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The invention adds a dimensional element by creating rolled-up rim portions that extend beyond the container opening. These three-dimensional rolled structures provide additional mechanical support and leverage the high stiffness of paperboard material to compensate for the reduced plastic content, maintaining rim strength despite using only a thin plastic foil layer.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Quantity of substance

If the plastic foil layer is made thin to reduce plastic use, then environmental friendliness is improved, but the separation difficulty during recycling worsens

Engineering Contradiction:

Improveplastic contentVSAvoidseparation ease

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The container is designed with clearly segmented layers: an outer paperboard layer and an inner plastic foil layer. The rolled-up rim portions are formed from the paperboard layer, creating a distinct structural element that facilitates separation. This segmentation makes it easier to manually or mechanically separate the thin plastic foil from the paperboard structure during recycling processes.

Inventive Principle:

Principle #1Segmentation

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

Reduces plastic content by up to 70% compared to prior art, enhances recyclability, and maintains structural integrity.

Implementation Method 1

the term 'thermoforming' should be understood as a process where a plastic sheet or foil is heated and then inserted into a mould where it is formed into a shape defined by the mould

Methodology Applied

Scientific EffectThermoforming:

Data Source

PatentUS12466605B2Container with paperboard outer layer and thin plastic foil inner layer

Publication Date: 2025.11.11 BERRY SUPERFOS RANDERS AS

AI summary

A container comprising a bottom and a sidewall extending upwards from the bottom and terminating at an upper free edge, said upper free edge of the sidewall forming an opening of the container, said sidewall and said bottom comprising an outer paperboard layer and a thin inner plastic foil layer, formed in a thermoforming operation, said upper free edge of the sidewall comprising a rim portion extending past the outer surface of the paperboard layer of the sidewall. The rim portion comprises a rolled up portion of an upper portion of the outer paperboard layer of the sidewall, said rolled up portion being covered by a portion of the thin inner plastic foil layer. In this way, a stiff upper rim is provided, while allowing the use of a very thin inner plastic foil layer.