Skived Flap Paper Container Moisture Barrier

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Solution Overview

Problem

Existing paper-based containers are prone to moisture ingress and content leakage due to their manufacturing process, which involves seams that can lead to improper adhesion and structural weakening, especially when storing liquids or semi-solids, and they are not resistant to prolonged storage periods.

Innovation Solution

A gable-top paper-based container with a low-density polyethylene coating on both surfaces and multiple skived flaps that are folded and adhered to create a seamless, moisture-resistant structure, preventing exposure of raw edges and ensuring the contents do not saturate the paperboard material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If paper-based containers are manufactured with seams through folding and adhesion, then the container can be formed from flat material, but the seams create improper adhesion and gaps that lead to moisture ingress and leakage

Engineering Contradiction:

Improvecontainer formationVSAvoidmoisture resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies a moisture-resistant coating (such as polyethylene or wax) on the paperboard surfaces, creating a thin film barrier that prevents moisture ingress through the seams and adhesion points, thereby maintaining reliability while preserving the ease of manufacture of folded paper containers

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent combines paperboard with moisture-resistant coatings or laminates to create a composite material structure that retains the formability of paper while adding protective properties that prevent leakage and moisture damage at seam locations

Inventive Principle:

Principle #40Composite materials

2Duration of action of stationary object

If paper-based containers are stored for prolonged periods, then they provide extended storage capability, but the contents saturate the paperboard material causing structural weakening

Engineering Contradiction:

Improvestorage periodVSAvoidmaterial integrity

Core Design Contradiction:

Duration of action of stationary objectVSStrength

Solution Approach 1:

The moisture-resistant coating acts as a barrier film that prevents contents from contacting and saturating the paperboard, allowing prolonged storage without structural degradation

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The composite structure of coated paperboard provides both the storage capacity of paper and the moisture barrier properties needed to maintain strength during extended storage periods

Inventive Principle:

Principle #40Composite materials

3Reliability

If plastic containers are used instead of paper-based containers, then leakage and moisture resistance are improved, but environmental pollution and lack of biodegradability worsen

Engineering Contradiction:

Improveleakage resistanceVSAvoidenvironmental pollution

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite material combining biodegradable paperboard with thin layers of moisture-resistant coating, achieving plastic-like leakage resistance while maintaining the biodegradability and environmental compatibility of paper materials

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the surface properties of paperboard through coating applications, changing its moisture resistance parameter from poor to good, thereby achieving plastic-like performance while retaining the environmental benefits of paper

Inventive Principle:

Principle #35Parameter changes

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 significantly reduces moisture and odor leakage, enhances the structural integrity of the container, and makes it more resistant to breakdown over time, providing a durable and eco-friendly alternative to single-use plastic containers.

Implementation Method 1

a low-density polyethylene coating on one or both surfaces of the container... prevents both moisture from entering the container along the flap and the contents of the container from saturating the paper

Methodology Applied

Scientific EffectBarrier effect:

Data Source

PatentUS11807429B2Multiple-skived paper-based container

Publication Date: 2023.11.07 CARTON SERVICE CSI LLC

AI summary

The present invention relates generally to a new and improved paper-based container. More specifically, the invention relates to a paper-based container that is comprised of a relatively low-density polyethylene coating on one or both surfaces of the container and at least two skive flaps, wherein each of said skive flaps is created during the manufacturing process. The skive flap further comprises at least one leading edge of the container body, and prevents unwanted moisture from entering the container and the contents of the container from saturating the paper-based material. One skive flap is preferably folded in a manner in which a portion of the outside surface of the container is adhered to the inside surface, a second skive flap is adhered to the outside surface and a third skive is formed at the bottom of the container.