Container having self-contained heater material
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Solution Overview
Problem
Conventional self-heating containers with air-activated materials face premature reaction issues due to inadequate oxygen barriers, leading to reduced heating capacity and shelf-life, as well as moisture and water vapor leakage, which compromises the effectiveness and longevity of the heating process.
Innovation Solution
A container design featuring a laminate structure with a first web adhered to a second web via an adhesive layer, where the second web has score lines defining plugs that are maintained within the layer to prevent premature air ingress, and a third web forming a holding space for contents, allowing controlled air entry to activate the air-activated material, while also incorporating metalized films for enhanced barrier properties and heat retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional self-heating containers use simple barrier structures, then manufacturing costs are reduced, but oxygen barrier performance is insufficient leading to premature reaction of air-activated material
Solution Approach 1:
The container employs a multi-layer composite structure consisting of an outer skin, inner skin, and intermediate layer. The intermediate layer specifically includes an oxygen barrier layer with oxygen transmission rate less than 0.5 cc/100 in2/24 hrs at 38°C/75% RH, combined with hydrogen venting pathways. This composite structure achieves superior oxygen barrier performance while managing hydrogen gas generation, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The container structure is segmented into distinct functional layers: outer skin for structural integrity, intermediate layer for oxygen barrier and hydrogen venting, and inner skin for content containment. The oxygen barrier function is further segmented into multiple sub-layers including EVOH or PVDC barrier layers. This segmentation allows each layer to optimize its specific function, achieving high oxygen barrier performance through coordinated layer interactions.
2Duration of action of stationary object
If the container uses adequate oxygen barrier layers, then shelf-life of air-activated material is prolonged, but manufacturing costs increase
Solution Approach 1:
The container is pre-configured with integrated oxygen barrier layers and hydrogen venting pathways during manufacturing. The intermediate layer is pre-formed with specific oxygen transmission properties and hydrogen venting capabilities. This preliminary action ensures long shelf-life (maintaining heating material effectiveness for extended periods) while avoiding complex post-manufacturing assembly steps, thus balancing durability with manufacturing ease.
Solution Approach 2:
The intermediate layer serves multiple functions simultaneously: it provides oxygen barrier protection, hydrogen venting pathways, and structural support. The outer and inner skins also contribute to oxygen barrier performance while providing mechanical strength and content containment. This multi-functionality reduces the need for separate dedicated components, simplifying manufacturing while ensuring long shelf-life.
3Reliability
If the container structure is made more complex to prevent moisture leakage, then heating effectiveness is improved, but device complexity increases
Solution Approach 1:
The container uses composite material structures where the outer skin, intermediate layer, and inner skin work together to provide moisture barrier performance. The intermediate layer's oxygen barrier materials (EVOH, PVDC) also provide moisture resistance. This composite approach achieves reliable moisture protection through material properties rather than complex structural additions, maintaining heating effectiveness while controlling complexity.
4Object-affected harmful factors
If hydrogen venting pathways are integrated into the barrier layers, then safety is improved, but the barrier integrity is compromised
Solution Approach 1:
The intermediate layer has locally differentiated properties: regions with high oxygen barrier density and regions with hydrogen venting pathways. The oxygen barrier layer maintains integrity in areas where oxygen transmission must be minimized, while hydrogen venting pathways are strategically positioned to allow hydrogen gas escape. This local quality differentiation allows simultaneous achievement of oxygen barrier reliability and hydrogen safety without compromising overall barrier integrity.
Solution Approach 2:
The intermediate layer acts as an intermediary between the oxygen barrier requirement and hydrogen venting requirement. It contains oxygen barrier materials that maintain oxygen transmission control while simultaneously providing controlled pathways for hydrogen gas to escape. This intermediary structure mediates between the conflicting requirements of oxygen barrier integrity and hydrogen venting, allowing both functions to coexist without compromising either.
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 effectively prolongs the shelf-life of the air-activated material, maintains the heating capacity, and ensures efficient heating of contents by preventing premature reactions and moisture/water vapor leakage, while reducing manufacturing costs and weight.
Implementation Method 1
an air-activated material disposed within the compartment... configured to react with air entering the compartment via the openings to activate the material
Data Source
Figure 1
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Figure 4
AI summary
A container (10) is provided that has a compartment (40) for storing an air-activated material (50) for heating contents. The compartment is formed between a first web (20) of material and a second web (30) of material. The first web includes a first film layer (22) laminated to a second film layer (24). A portion of the first film layer of the first web can be separated from the second film layer to reveal openings (65) in the first film layer that allow air to enter the compartment. When the air contacts the air-activated material to activate the material, an exothermic reaction takes place that serves to produce heat, such as to heat the contents of the container.