Seamless Cellulose Container Thermoforming for Deep Shapes
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Solution Overview
Problem
Cellulose-based containers face challenges in achieving complex shapes due to lack of elasticity, requiring joints or seams that can lead to leakage and necessitate additional manufacturing steps, and often require extensive refinement of fibers.
Innovation Solution
A seamless and jointless container made of blown cellulose fibers, with a hydrophobic and lipophobic layer, is manufactured through a thermoforming process involving a 3D mat compression, using softwood fibers with limited treatment, and optional coatings for properties like waterproofness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cellulose mats are thermoformed to create containers, then containers can be made from natural fibers, but the lack of elasticity prevents achieving complex shapes and adding depth
Solution Approach 1:
The container is divided into a body portion and a separate bottom piece that can be attached later. This segmentation allows the main body to be formed with adequate depth while the bottom piece provides the necessary structural support and complexity, overcoming the elasticity limitation of cellulose material
Solution Approach 2:
The invention transitions from attempting to form the entire container in a single piece to a multi-component assembly process. By adding the dimension of assembly steps (separating body formation from bottom attachment), the solution achieves complex shapes without requiring the cellulose to be sufficiently elastic for monolithic forming
2Shape
If joints or seams are added to achieve deeper shapes, then container depth is increased, but leakage risk increases and additional manufacturing steps are required
Solution Approach 1:
The problematic joints and seams are completely removed from the container body by forming it as a seamless single piece. The bottom piece is attached in a controlled manner that eliminates the need for traditional joints, thereby maintaining leakage resistance while achieving the necessary depth
Solution Approach 2:
The design anticipates potential leakage issues by pre-planning the seamless construction approach. The bottom piece is designed to fit precisely with the body portion, creating a leak-proof assembly before any actual use or filling occurs
3Ease of manufacture
If extensive refinement is applied to cellulose fibers, then containers can be manufactured, but sustainability and cost-effectiveness are reduced
Solution Approach 1:
The invention changes the key parameter from extensive chemical/mechanical refinement to minimal processing. By adjusting the processing parameters to use near-raw cellulose fibers with limited treatment, the solution maintains manufacturability while preserving fiber content and improving sustainability
Solution Approach 2:
Instead of uniformly refining all cellulose fibers extensively, the process applies minimal processing locally, preserving the natural properties of the fibers while achieving sufficient workability for container formation
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 process enables the production of cellulose containers with enhanced structural integrity and reduced manufacturing complexity, allowing for deeper shapes without seams and adhesives, while maintaining sustainability and recyclability.
Implementation Method 1
pressing the layer of cellulose fibers in the mold, whereby the cellulose is thermoformed into a monoblock piece of interconnected cellulose fibers
Implementation Method 2
one of the at least two layers is a hydrophobic layer
Implementation Method 3
one of the at least two layers is a lipophobic layer
Data Source
AI summary
A container or lid comprising: a body of molded cellulose, the body of molded cellulose defining at least one wall, the wall having an outer surface and an inner surface. The container or lid has is made of blown cellulose fibers from a mat compressed in at least one compression step. A method for forming a container or lid having a cellulose body may also be provided.