Biopolymer coated fiber food service items
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Disposable food service items made from paperboard coated with non-biodegradable polymers like polyethylene, polypropylene, or polyethylene terephthalate do not degrade quickly in landfills, leading to long-term landfill persistence despite providing poor water and grease resistance.
Innovation Solution
A biodegradable food service item with a substrate comprising cellulosic fibers and a coating of polyhydroxyalkanoates, along with surfactants, rheology modifiers, defoamers, and biocides, applied at specific weight percentages to achieve water and grease resistance comparable to non-biodegradable coatings, while ensuring biodegradability through specific manufacturing processes involving heat and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If paperboard is coated with non-biodegradable polymers like polyethylene, polypropylene, or polyethylene terephthalate, then water and grease resistance is significantly improved, but the coating does not readily degrade or decompose after landfill disposal, causing items to subsist in landfills for centuries
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by using biodegradable polymers (such as polyhydroxyalkanoates, starch, or cellulose) instead of conventional non-biodegradable polymers. This parameter change maintains the protective function while enabling biodegradation, thus resolving the contradiction between water/grease resistance and landfill persistence.
Solution Approach 2:
The patent employs composite material structures where biodegradable polymers are combined with cellulosic fibers or other natural materials to create a coating that provides both protective properties (water and grease resistance) and biodegradability. The composite nature allows the material to function as a barrier while remaining environmentally degradable.
2Duration of action of stationary object
If paperboard is used as a substrate for food service items, then the items are biodegradable, but the paperboard rapidly soaks up water and grease, compromising the strength of the paperboard
Solution Approach 1:
The patent modifies the surface properties of the biodegradable paperboard substrate by applying a biodegradable polymer coating. This changes the surface energy and porosity parameters, creating a barrier that prevents water and grease penetration while maintaining the bulk biodegradability of the paperboard substrate.
Solution Approach 2:
The patent creates a composite structure consisting of a biodegradable paperboard substrate combined with a biodegradable polymer coating layer. This composite provides both the biodegradability of the paperboard and the water/grease resistance of the polymer coating, resolving the contradiction between these two properties.
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 biodegradable food service items exhibit excellent water and grease resistance comparable to items coated with non-biodegradable polymers but remain fully degradable, meeting environmental sustainability goals.
Implementation Method 1
the coating provides good water and grease resistance - i.e. water and grease resistance comparable to that provided by conventional, nonbiodegradable coatings
Implementation Method 2
specific manufacturing processes involving heat and pressure
Implementation Method 3
specific manufacturing processes involving heat and pressure
Implementation Method 4
both the substrate and the coating are fully biodegradable
Data Source
AI summary
A biodegradable food service item is disclosed, which includes a biodegradable substrate having at least one food contact surface. This substrate is made of cellulosic fibers. The food service item also includes a coating applied over the at least one food contact surface. This coating is made up of from about 25 to about 60 weight percent of at least one biodegradable polymer, such as polyhydroxyalkanoates. A method for making the biodegradable food service item is also disclosed.