Cellular Polypropylene Cup Forming Crease Elimination
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Solution Overview
Problem
Existing polymeric materials used for forming insulated containers often suffer from creasing and wrinkling issues during the cup-forming process, leading to unsatisfactory surface quality and usability.
Innovation Solution
The use of a cellular polypropylene-based material with a specific crystalline structure, where the outside-of-extruded-tube (OET) surface is oriented inside the cup, and the inside-of-extruded-tube (InET) surface is oriented outside, combined with controlled cooling rates to create a beta-crystalline phase detectable by X-ray diffraction but not by differential scanning calorimetry, results in a crease-free and wrinkle-free surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional polymeric materials are used for forming insulated containers, then the material can be easily processed, but creasing and wrinkling occur during cup-forming leading to unsatisfactory surface quality
Solution Approach 1:
The patent applies parameter changes by controlling the crystalline structure of polypropylene through specific cooling rates during extrusion. By adjusting the cooling rate parameter, the patent creates a beta-crystalline phase that fundamentally changes the material's mechanical properties, making it resistant to creasing and wrinkling during cup-forming while maintaining ease of processing
Solution Approach 2:
The patent utilizes phase transitions by inducing beta-crystalline phase formation in polypropylene through controlled cooling. This phase transition from conventional crystalline structures to beta-crystalline phase during extrusion creates a material with superior surface quality and crease resistance, directly resolving the contradiction between manufacturing precision and ease of manufacture
2Manufacturing precision
If the extrudate surface morphology does not have beta-crystalline phase, then the material is easier to process, but visible deep creases and wrinkles appear inside the formed insulative cup
Solution Approach 1:
The patent applies preliminary action by establishing the beta-crystalline phase structure during the extrusion process before the cup-forming operation. By pre-controlling the crystalline morphology in the extruded tube, the material is prepared in advance to resist creasing and wrinkling during subsequent forming, eliminating the need for additional complex controls during cup-making
Solution Approach 2:
The patent changes the crystalline structure parameter by inducing beta-phase formation through specific cooling rates. This parameter change transforms the material's inherent properties, providing crease-free surfaces without requiring complex device controls during the forming process, thus resolving the contradiction between manufacturing precision and device complexity
3Manufacturing precision
If die cut parts are not oriented in cross-web direction, then the cutting process is simpler, but creasing and wrinkling cannot be eliminated in the insulative cup
Solution Approach 1:
The patent applies asymmetry by orienting die-cut parts in a specific cross-web direction relative to the extrusion direction. This asymmetric orientation arrangement, combined with the beta-crystalline phase structure, creates anisotropic mechanical properties that prevent creasing and wrinkling during forming, while the orientation rule itself remains simple to implement, resolving the contradiction between surface smoothness and productivity
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 approach effectively eliminates creasing and wrinkling, ensuring a high-quality, usable insulative cup with improved resistance to compression forces and surface smoothness, as evidenced by microscopy and X-ray diffraction analysis.
Implementation Method 1
an extruded tube of insulative cellular polypropylene-based material has a surface morphology that includes a beta-crystalline polypropylene phase identified by X-ray wide angle diffraction analysis
Implementation Method 2
a beta-crystalline polypropylene phase identified by X-ray wide angle diffraction analysis
Implementation Method 3
X-ray wide angle diffraction analysis
Implementation Method 4
controlled cooling rates to create a beta-crystalline phase
Data Source
AI summary
A formulation includes a polymeric material and can be used to form an insulated container.