Reheatable Insulated Container With Polyester Fabric Spin Welding
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Solution Overview
Problem
Conventional insulated containers use non-recyclable and non-eco-friendly rigid PU foam insulation, which is unsafe for microwave and dishwashing, and allows liquid to seep between layers, causing hygiene issues and disassembly due to expansion.
Innovation Solution
A container with a body assembly comprising an outer polypropylene layer, a middle nonwoven polyester fabric insulation layer, and an inner stainless steel layer, assembled using spin welding and insert moulding techniques for absolute sealing and recyclable insulation, allowing safe use in microwaves and dishwashers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If rigid PU foam insulation is used in conventional insulated containers, then insulation performance is improved, but the container becomes unsafe for microwave and dishwashing use due to expansion properties
Solution Approach 1:
The patent changes the material parameters of the insulation layer by using nonwoven polyester fabric instead of rigid PU foam. This material substitution eliminates the expansion issue under microwave radiation while maintaining thermal insulation performance, directly resolving the contradiction between insulation effectiveness and safety for microwave/dishwashing use.
Solution Approach 2:
The patent creates a composite structure with multiple layers including outer plastic body, middle nonwoven polyester insulation layer, and inner stainless steel container. This composite design combines materials with different properties to achieve both good insulation and microwave safety, as the polyester fabric does not expand under microwave radiation unlike PU foam.
2Ease of manufacture
If simple mechanical push snap fit assembly is used in conventional insulated containers, then manufacturing ease is improved, but absolute sealing between layers cannot be achieved allowing liquid seepage
Solution Approach 1:
The patent replaces the mechanical push snap fit assembly system with ultrasonic welding technology. This substitution eliminates the sealing gaps and liquid seepage issues inherent in mechanical assembly while maintaining manufacturing efficiency. The ultrasonic welding creates strong, leak-proof bonds between the plastic body, insulation layer, and stainless steel container.
3Temperature
If non-recyclable rigid PU foam insulation is used, then insulation performance is improved, but environmental friendliness and recyclability deteriorate
Solution Approach 1:
The patent changes the material composition parameter of the insulation layer from non-recyclable rigid PU foam to recyclable nonwoven polyester fabric. This material parameter change maintains thermal insulation performance while improving environmental compatibility and recyclability, directly addressing the contradiction between insulation effectiveness and environmental harm.
4Ease of manufacture
If open curvatures and inaccessible spaces are present in conventional insulated containers, then manufacturing ease is improved, but cleaning accessibility deteriorates leading to unhygienic conditions
Solution Approach 1:
The patent uses ultrasonic welding to create smooth, continuous surfaces without open curvatures or inaccessible spaces. This welding method eliminates the need for complex mechanical joints and crevices that trap food particles, making the container surface fully accessible for cleaning while maintaining manufacturing efficiency.
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 container provides effective thermal insulation, prevents liquid seepage, and maintains structural integrity during microwave exposure and washing, ensuring food remains hygienic and hot for extended periods without physical or chemical damage.
Implementation Method 1
The middle layer is made up of a nonwoven polyester fabric... with nonwoven polyester fabric providing effective insulation
Implementation Method 2
the plastic top lid, the inner lid and the bowl are sealed by using a plastic to plastic fusion using the spin welding technique
Implementation Method 3
The inner stainless steel (SS) container is insert molded between a fused layer of plastic ring, the outer plastic body and the middle layer
Data Source
AI summary
The various embodiments herein provide an insulated container. The container comprises a body assembly and a lid assembly. The body assembly comprises of an outer plastic body and a plastic ring insert molded with an inner stainless steel (SS) container. The inner SS container has a non-woven polyester fabric acting as an insulation material. The non-woven polyester fabric is enclosed in between the outer plastic body and the inner SS container. The lid assembly comprises of a plastic top lid, an inner lid and a bowl with non-woven polyester fabric acting as insulation. The polyester fabric is sandwiched between the plastic top lid, the inner lid and the bowl. In the body assembly, the outer plastic body and the inner plastic ring is joined together using a spin welding technique. In the lid assembly the top lid, inner lid and bowl are joined together using spin welding technique.