Repulpable Insulated Paper with Bismuth Oxychloride Coating
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Solution Overview
Problem
Conventional insulated paper products used for wrapping food, such as those with aluminum foil, are not recyclable, biodegradable, or safe for food contact, and pose environmental and health risks due to their persistence in landfills and potential neurodegenerative effects when ingested.
Innovation Solution
Development of a repulpable insulated paper product with a thermally insulating coating that is biodegradable, recyclable, and food contact safe, comprising wood pulp fibers and insulating materials like bismuth oxychloride, mica, and zinc oxide, which provides moisture and grease resistance while maintaining thermal insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aluminum foil is used for thermal insulation, then thermal insulation performance is improved, but environmental persistence and non-recyclability worsen
Solution Approach 1:
The patent removes aluminum foil from the paper product structure entirely, extracting the problematic component that causes environmental persistence while maintaining thermal insulation through alternative means (paper construction and coatings)
Solution Approach 2:
The patent changes the material composition parameters from aluminum-based to paper-based with alternative coatings, transforming the product from non-recyclable to recyclable while maintaining insulating properties through different material characteristics
2Temperature
If aluminum foil is laminated to paper, then thermal insulation and structural resiliency are improved, but food safety and health risks worsen
Solution Approach 1:
The patent extracts aluminum foil from the product structure, eliminating the source of neurodegenerative disease risks and food safety concerns while maintaining protective functions through paper-based construction
Solution Approach 2:
The patent uses composite paper structures with multiple layers and coatings (including wax, silicone, or fluorocarbon treatments) to achieve both thermal insulation and food safety, creating a composite material system that satisfies multiple requirements without aluminum
3Ease of manufacture
If low basis weight paper with coating is used, then cost and thinness are improved, but moisture and grease resistance worsen
Solution Approach 1:
The patent modifies the paper parameters by treating it with wax, silicone, or fluorocarbon coatings that fundamentally change the surface properties to provide moisture and grease resistance while maintaining low basis weight and thinness
Solution Approach 2:
The patent creates a composite structure combining low basis weight paper with protective coating layers, achieving both cost-effectiveness and reliable moisture/grease resistance through the synergistic combination of 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 solution effectively insulates food, is safe for food contact, and can be recycled or biodegraded, addressing environmental concerns and health risks associated with traditional products.
Implementation Method 1
coating with a low thermal conductivity and/or a low thermal emissivity
Implementation Method 2
insulating materials included within the coating... provides thermal insulation
Data Source
Figure 1~3
Figure 4A~5
Figure 6A
AI summary
Paper products with a thermally insulating coating are disclosed. Methods of making and using thermally insulated paper products are also disclosed.