Separable Polymeric Lining for Recyclable Paper Cups
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Solution Overview
Problem
Disposable paper cups and containers for hazardous liquids face challenges in recycling due to laminated card materials, which are difficult to separate and contaminate paper pulp, leading to significant waste and environmental issues, while existing solutions for hazardous liquids are costly and inefficient in disposal.
Innovation Solution
A method for creating a separable inner lining and outer shell for cups, where the inner lining is made from a thin sheet of polymeric material bonded along one edge, forming a bag that conforms to the shell's shape, allowing easy peeling and separation, using a non-laminated paperboard shell for recyclability and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laminated card with polymeric coating is used to make disposable cups, then the cups have waterproof and liquid barrier properties, but the plastic coating prevents decomposition and contaminates paper pulp during recycling
Solution Approach 1:
The cup is divided into two separable components: a paperboard outer shell and a polymeric inner lining. The lining is inserted into the shell and adhered to the inner surface, allowing the components to be separated after use. This segmentation enables the paper shell to be recycled independently while the plastic lining is removed and disposed of separately, eliminating contamination of paper pulp during recycling while maintaining waterproof properties during use.
2Reliability
If plastic coating is applied to paper-based substrate, then liquid barrier function is improved, but the coating prevents water from breaking up paper fibres during pulping
Solution Approach 1:
The cup structure separates the plastic lining from the paper shell, allowing the paper shell to undergo conventional pulping processes without plastic interference. The plastic lining is removed before recycling, enabling efficient paper fibre breakdown while maintaining the liquid barrier function during the cup's service life.
3Object-generated harmful factors
If removable lining is added to container, then disposal cost and complexity is reduced, but the container structure becomes more complex
Solution Approach 1:
The container is designed with a removable inner lining that can be separated from the outer shell. This segmentation allows the lining to be removed and disposed of separately, reducing disposal costs and complexity. The simple insertion and adherence mechanism keeps the structural complexity manageable while achieving the benefit of separate disposal.
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
Enables the cups to be recycled efficiently, reduces contamination, and facilitates cost-effective disposal of hazardous liquid containers by allowing the inner lining to be removed and disposed of separately from the outer shell, addressing the environmental and economic challenges of existing methods.
Implementation Method 1
heating the second part of the lining such that the second part of the lining shrinks around the outside of the shell and the lining conforms to the rolled rim and the upper region of the shell
Implementation Method 2
adhering the first part of the lining to an internal surface of the shell by means of the adhesive
Data Source
Figure 1~3
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Figure 5
AI summary
A method of making a container (2, 30) having a separable inner lining (6) and outer shell (4) comprises the steps of: forming an outer shell; pre-forming a flexible lining, at least a part of the lining conforming to a complete internal shape of the shell; inserting the preformed lining into the shell so that a first part of the lining is within the shell and a second part of the lining protrudes from the opening of the shell; adhering the first part to an internal surface (8) of the shell; conforming the second part to an external surface of the shell; and attaching to the lining around said rim a sealing layer covering the opening, and the adhesion between the lining and the internal surface of the shell being such that the lining is peelable from the shell while remaining intact.