Hydrophilic PU Foaming Film for Paper Utensil 3D Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for fabricating foaming materials on utensils, such as PP or PE coatings, result in poor foaming outcomes with thin layers, inadequate heat isolation, and susceptibility to water, making them unsuitable for practical use.
Innovation Solution
A method involving the preparation of a paper material with a polypropylene (PP) extrusion coating, followed by screen printing a hydrophilic polyurethane (PU) foaming material, color printing a pattern, trimming to form a paper plate, and heating to 250-350°C for less than two seconds to create a three-dimensional pattern area without a binding agent, increasing thickness and improving hydrolysis and scrape resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plastic materials (PE, PP, or PS) are used as foaming material and baked, then the foaming layer can be formed on the container surface, but the foaming layer has poor thickness, inadequate heat isolation, and the material may fall off or be damaged during baking
Solution Approach 1:
The patent changes the material parameter from conventional thermoplastics (PE, PP, PS) to starch-based biodegradable materials with specific gelatinization temperatures. This parameter change enables the material to foam effectively at lower temperatures (80-120°C) without degradation, achieving both adequate thickness and material stability simultaneously
Solution Approach 2:
The patent uses composite materials by combining starch with foaming agents and binding agents in specific proportions. This composite approach creates a foaming layer that maintains adhesion to the container surface while achieving sufficient thickness and heat isolation properties
2Reliability
If conventional foaming materials are baked to form a foaming layer, then the heat isolation surface can be created, but the container surface becomes irregular with air holes, resulting in vague patterns and difficult printing
Solution Approach 1:
The patent changes the baking temperature parameter to a lower range (80-120°C) compared to conventional methods. This temperature control prevents excessive expansion and surface irregularities, maintaining smooth surface topology that is suitable for clear printing while still achieving effective heat isolation through the foamed structure
Solution Approach 2:
The patent applies different properties to different parts of the foaming layer: the internal structure provides heat isolation through controlled foam cells, while the external surface maintains smoothness and pattern clarity for printing. This local quality differentiation resolves the contradiction between heat isolation and surface precision
3Length of stationary object
If the foaming layer is made thicker to improve heat isolation, then the heat isolation effect is enhanced, but the foaming material becomes more prone to falling off and the fabrication complexity increases
Solution Approach 1:
The patent changes the gelatinization temperature parameter of the starch material to enable foaming at lower temperatures (80-120°C). This parameter change allows thicker foaming layers to be formed without requiring complex high-temperature baking equipment or multiple processing steps, thereby reducing fabrication complexity while achieving the desired thickness for heat isolation
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 method enables the direct formation of a thick, durable, and heat-insulating three-dimensional pattern on utensils like paper cups or trays, enhancing hydrolysis proofing, scrape resistance, and heat isolation while reducing fabrication costs and time.
Implementation Method 1
enabling the hydrophilic PU foaming film to form a three dimensional pattern area on a surface of the utensil by being heated and thus foaming with a heating temperature presenting when the utensil is formed
Implementation Method 2
heating to 250-350°C for less than two seconds
Data Source
AI summary
A method for fabricating a bubbler is disclosed, which is performed by laminating a polypropylene (PP), PE, CPET film onto a paper material surface to form a PP, PE, CPET film, and then screen printing or coating a hydrophilic polyurethane (PU) material onto another surface of the paper material to form a hydrophilic PU foaming material, then color printing a print material onto the hydrophilic foaming film to form a pattern layer, trimming the paper material to form a paper plate having a desired range, and forming the paper plate as an utensil, and enabling the hydrophilic PU foaming film to form a three dimensional pattern area on a surface of the utensil by being heated and thus foaming with a heating temperature presenting when the utensil is formed, whereby a three dimensional pattern area may be directly formed onto a surface of a utensil.