Pulp Molded Container Composite Coating for Hot Oil Resistance

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Solution Overview

Problem

Current pulp molded containers lack hot oil resistance and gas barrier properties, making them unsuitable for containing ready-to-eat food, especially when exposed to high temperatures, and they are not environmentally friendly due to high plastic content.

Innovation Solution

A fabricating method involving a mixture of long and short fiber pulp, with additives like nanocellulose and starch, followed by heat compression molding, to create a pulp molded container with improved hot oil resistance and gas barrier properties, while being environmentally sustainable.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If plastic containers are used to contain ready-to-eat food, then gas barrier, hot oil resistance, heat sealing and waterproof properties are improved, but environmental protection requirements are not met due to non-decomposable materials

Engineering Contradiction:

Improvegas barrier and hot oil resistanceVSAvoidenvironmental pollution from non-decomposable plastic

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses a composite coating system consisting of a first coating layer (plastic resin providing hot oil resistance) and a second coating layer (biodegradable material providing gas barrier and environmental sustainability). This multi-layer composite structure combines the advantages of different materials to simultaneously achieve reliable hot oil resistance, gas barrier properties, and environmental protection through biodegradability.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If common pulp molded containers are used for food storage, then environmental protection requirements are met, but gas barrier and oil resistance are poor making them unsuitable for oven use

Engineering Contradiction:

Improveenvironmental protectionVSAvoidgas barrier and hot oil resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies a composite coating system to the pulp molded container, where the first coating layer of plastic resin provides the necessary hot oil resistance and sealability, while the second coating layer of biodegradable material provides gas barrier properties and maintains environmental sustainability. This allows the container to achieve reliable performance for oven use while remaining environmentally friendly.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the physical and chemical parameters of the pulp molded container by applying coating layers with specific properties. The first coating layer changes the surface parameters to provide hot oil resistance, while the second coating layer adjusts the gas permeability parameters to achieve low air permeance, transforming the container from unsuitable for oven use to meeting high-temperature requirements.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If plastic film is pasted on pulp molded container to improve performance, then hot oil resistance and gas barrier are improved, but plastic content increases and recycling becomes difficult

Engineering Contradiction:

Improvehot oil resistance and gas barrierVSAvoidplastic content and recyclability

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent uses a composite coating structure where the first coating layer (plastic resin) and second coating layer (biodegradable material) are applied in sequence. This composite approach allows the container to achieve improved hot oil resistance and gas barrier properties while incorporating biodegradable materials that enhance recyclability and reduce plastic waste compared to a single plastic film coating.

Inventive Principle:

Principle #40Composite materials

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 results in a pulp molded container with enhanced hot oil resistance and low air permeance, allowing safe storage and heating of food, and meets environmental protection requirements by reducing plastic content.

Implementation Method 1

In the pulping step, the aqueous pulp solution is mechanically fibrillated to form a fibrillated pulp

Methodology Applied

Scientific EffectMechanical fibrillation:

Implementation Method 2

In the additive adding step, an additive is added into the fibrillated pulp and mixed to form a paper pulp

Methodology Applied

Scientific EffectMixing:

Implementation Method 3

In the heat compression molding step, the paper pulp is formed into a pulp molded container by heat compression molding

Methodology Applied

Scientific EffectHeat compression molding:

Data Source

PatentUS20240003094A1Pulp molded container and fabricating method thereof

Publication Date: 2024.01.04 INTLPAK ENTERPRISES CORP

AI summary

A fabricating method of a pulp molded container includes providing a main material, performing a dispersing step, performing a pulping step, performing an additive adding step, and performing a heat compression molding step. The main material includes a long fiber pulp and a short fiber pulp. In the dispersing step, the main material is dispersed evenly in water to form an aqueous pulp solution. In the pulping step, the aqueous pulp solution is mechanically fibrillated to form a fibrillated pulp. In the additive adding step, an additive is added into the fibrillated pulp and mixed to form a paper pulp. In the heat compression molding step, the paper pulp is formed into the pulp molded container by heat compression molding.