Porous Board Layer for Thermal Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional board drinking cups have poor thermal insulation, causing discomfort when holding hot or cold beverages due to their thin material, and existing solutions like foamed polymer coatings can compromise print quality with surface irregularities.
Innovation Solution
Incorporating a polymer with high melt viscosity into the fibre-based board layer, which foams when heated by humidity, creating a porous structure for improved insulation without affecting the surface smoothness or print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a polymer coating layer is foamed to improve thermal insulation, then thermal insulation capacity is improved, but surface smoothness deteriorates
Solution Approach 1:
The patent applies local quality by creating a porous structure only in the interior of the board layer while keeping the surface smooth. Polymer particles are distributed throughout the board layer, and upon heating, they expand to form pores internally without affecting the outer surface quality, thus achieving thermal insulation without compromising printability.
Solution Approach 2:
The patent uses the rapid expansion of polymer particles upon heating to skip directly to the desired porous structure. The polymer particles are heated above their melting point, causing them to expand rapidly and form pores within the board layer, achieving the thermal insulation function without the need for slow, controlled foaming processes that might affect surface quality.
2Loss of energy
If the board layer is made thicker to improve thermal insulation, then thermal insulation capacity is improved, but the cup design flexibility deteriorates
Solution Approach 1:
The patent changes the physical parameters of the board layer by incorporating polymer particles that undergo phase change upon heating. The polymer particles transition from a dense state to an expanded porous state, fundamentally altering the thermal properties of the board without changing its thickness or basic structure, thus maintaining design flexibility while improving insulation.
Solution Approach 2:
The patent creates a composite material by combining fibre-based board with polymer particles. This composite structure provides both the structural integrity of the board and the thermal insulation properties of the porous polymer network, achieving enhanced insulation without increasing thickness or compromising design adaptability.
3Loss of energy
If polymer particles are distributed in the pulp, then porous structure is formed for insulation, but even distribution is difficult to achieve
Solution Approach 1:
The patent uses an intermediary substance or process to facilitate the even distribution of polymer particles in the pulp. The polymer particles are likely surface-modified or introduced through a carrier medium that ensures uniform dispersion during the papermaking process, eliminating clumping and achieving consistent thermal insulation properties throughout the board layer.
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 method enhances thermal insulation of board cups by creating a porous structure within the board layer, maintaining a smooth surface and high-quality printing, effectively preventing finger burns from hot drinks and discomfort from cold drinks.
Implementation Method 1
the board layer containing humidity is heated so that the polymer melts and water vapour bubbles penetrate into it, making the layer porous
Implementation Method 2
the polymer melts and water vapour bubbles penetrate into it
Implementation Method 3
water vapour bubbles penetrate into it, making the layer porous
Implementation Method 4
making the layer porous
Implementation Method 5
improve the thermal insulation capacity of the cup body
Data Source
AI summary
The invention relates to a method of manufacturing board (2), a board provided by the method, and a container formed from the same, such as a disposable drinking cup. According to the invention, fiber-based stock is doped with a polymer (6), ending in a pulp web that is formed of this pulp on a board machine wire, and in a board layer (3) that is obtained from the same by pressing and drying. When the board layer is heated, the polymer melts and water vapor bubbles penetrate it, rendering the layer porous. The polymer used for the doping can comprise, for example, a low density polyethylene (LDPE) that has a melt viscosity of about 15. Pore-generating heating can be carried out for the board or only for the container manufactured from it. The porous layer prevents the hot drink enjoyed from the cup from burning the fingers of the user.