Recyclable Waterproof Corrugated Container with Anti-Wicking Lid
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Solution Overview
Problem
Corrugated paperboard containers used for shipping perishable goods in wet conditions suffer from structural integrity issues due to water absorption, and existing waterproofing solutions with petroleum-based waxes or polymers make the containers non-recyclable.
Innovation Solution
A waterproof, anti-wicking, and recyclable corrugated container design featuring inner and outer waterproof liners and a score/crease line on the lid to prevent water wicking, combined with a gusseted two-piece structure that includes a telescopically engaged lid and base, utilizing Kraft poly film liners and Climaguard corrugation medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petroleum-based waxes or polymer compositions are applied to the walls of the container, then waterproof performance is improved, but recyclability deteriorates
Solution Approach 1:
The patent changes the material parameter from petroleum-based waxes/polymers to plant-based waxes (carnauba, beeswax, paraffin, microcrystalline wax). This parameter change maintains the waterproofing function while improving recyclability, as plant-based waxes are biodegradable and do not interfere with paper recycling processes.
Solution Approach 2:
The patent enables the container to be fully recovered and recycled after use. By using plant-based waxes instead of petroleum-based materials, the entire corrugated container structure can be recycled through standard paper recycling processes, allowing the material to be discarded responsibly and recovered for new products.
2Adaptability or versatility
If untreated paperboard is used, then recyclability is maintained, but structural integrity deteriorates when exposed to water
Solution Approach 1:
The patent creates a composite structure by impregnating the corrugated paperboard with plant-based wax compositions. The wax penetrates and binds with the paper fibers, creating a composite material that combines the recyclability of paper with the water-resistant properties of wax, thereby maintaining both structural integrity and recyclability.
Solution Approach 2:
The patent changes the physical-chemical parameters of the paperboard by impregnating it with wax. This treatment modifies the paperboard's properties to be water-resistant while preserving its base material characteristics, allowing it to maintain structural integrity in wet conditions and remain recyclable through standard paper recycling processes.
3Reliability
If water-resistant treatments are applied to the corrugation medium, then waterproof performance is improved, but material costs increase
Solution Approach 1:
The patent uses inexpensive plant-based waxes that can be applied in small quantities through impregnation. These affordable natural waxes provide effective waterproofing without the high costs associated with petroleum-based polymers, making the treatment economically viable for disposable corrugated containers.
Solution Approach 2:
The plant-based wax composition self-impregnates the corrugated paperboard structure, utilizing the material's own porosity and surface characteristics to absorb and distribute the waterproofing agent. This self-service mechanism reduces the need for complex application equipment and additional materials, thereby controlling costs.
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 solution provides a structurally sound, recyclable container that maintains integrity in wet environments, prevents water from rising into the corrugation medium, and reduces material costs while ensuring the container remains recyclable.
Implementation Method 1
waterproof liners on the inner sides and outer side of the walls of the container to prevent liquids such as water from reaching the corrugation medium
Implementation Method 2
prevents water from rising into the corrugation medium
Implementation Method 3
The smaller flute opening at the crease line causes the water to stay lower in the flute than the depth of the water outside the container by use of water pressure characteristics (i.e., static head pressure)
Data Source
AI summary
A waterproof, anti-wicking, and fully recyclable corrugated container comprises a base portion having a bottom wall, a pair of opposite side walls, a pair of opposite end walls, and a plurality of joined flaps foldably joined with the side walls and the end walls. Each of the plurality of the joined flap folds onto itself to form a gusset that is attached to the respective side walls. A lid portion is telescopically engaged over the base portion such that is coextensive in length and width with the base portion side walls and end walls. The lid portion comprises a score or crease line formed along near free edge of the side walls to inhibit liquid from traveling up through the side walls.