Antimicrobial Masterbatch Carrier for Polymer Packaging
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Solution Overview
Problem
Current polymer substrates used in packaging materials face challenges in maintaining food safety and shelf life due to contamination from pathogens, as existing antimicrobial additives are ineffective and prone to heat-induced degradation, and the surface/volume ratio of ground particles is low, compromising their performance.
Innovation Solution
An additive composition comprising a carrier material, a distinct antimicrobial substance, and a food preservative, which provides a synergistic antimicrobial effect, is incorporated into polymer substrates, enhancing their antimicrobial properties and extending the shelf life of packaged food while preserving organoleptic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimicrobial additives are incorporated into polymer packaging materials, then the antimicrobial efficacy is improved, but the additives are prone to heat-induced degradation during processing
Solution Approach 1:
The patent introduces a masterbatch carrier as an intermediary material that protects the antimicrobial additive from direct heat exposure during processing. The masterbatch acts as a protective vehicle, allowing the additive to be incorporated into the polymer substrate through extrusion while minimizing thermal degradation. This mediator approach enables the additive to survive the processing temperature range.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the antimicrobial additive by dispersing it within a masterbatch carrier before final incorporation. This pre-dispersion in a carrier material alters the thermal history and exposure conditions of the additive, reducing direct heat damage while maintaining its bioactivity for antimicrobial function.
2Ease of manufacture
If additive particles are ground using conventional methods, then they can be incorporated into polymer substrates, but the surface/volume ratio is low and dispersion is poor
Solution Approach 1:
The patent segments the antimicrobial additive into fine particles and pre-disperses them within a masterbatch carrier material. This segmentation into smaller units within the carrier enables better distribution when the masterbatch is subsequently incorporated into the polymer substrate, achieving superior dispersion quality compared to adding bulk additive particles directly.
Solution Approach 2:
The masterbatch carrier serves as an intermediary medium that facilitates uniform distribution of the antimicrobial additive particles. The carrier material acts as a vehicle that transports and distributes the fine additive particles evenly throughout the polymer substrate during extrusion, overcoming the poor dispersion achieved by direct particle incorporation.
3Ease of manufacture
If grinding methods use friction between components, then particles can be ground, but heat is generated that adversely affects additive properties
Solution Approach 1:
The masterbatch carrier acts as a protective intermediary that shields the antimicrobial additive from excessive heat generated during grinding and extrusion. The carrier material absorbs and distributes thermal energy, preventing localized overheating that would degrade the additive's chemical structure and antimicrobial properties.
Solution Approach 2:
The patent changes the thermal parameters by incorporating the additive into a masterbatch carrier before final processing. This pre-incorporation alters the thermal history and heat distribution during subsequent extrusion, reducing peak temperatures and thermal degradation of the sensitive antimicrobial components.
4Ease of manufacture
If ground particles are incorporated into polymer substrates, then the additive can be applied, but the particles are visible and poorly dispersed
Solution Approach 1:
The patent segments the antimicrobial additive into fine particles and pre-distributes them within the masterbatch carrier. This segmentation creates numerous small units that disperse more uniformly when the masterbatch is incorporated into the polymer substrate, eliminating visible particle aggregation and achieving homogeneous distribution throughout the material.
Solution Approach 2:
The masterbatch carrier serves as an intermediary vehicle that ensures uniform distribution of the antimicrobial additive particles. During extrusion, the carrier material facilitates even dispersion of the fine particles throughout the polymer substrate, preventing particle aggregation and achieving consistent distribution that maintains both cosmetic appearance and functional performance.
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 additive composition effectively reduces microbial contamination, extends the shelf life of food products, and maintains the quality and freshness of packaged items by providing enhanced antimicrobial activity and improved dispersion of antimicrobial agents within the polymer substrate.
Implementation Method 1
The particular combination of an antimicrobial substance and a food preservative which are different from each other provides a synergistic antimicrobial effect
Data Source
AI summary
The present invention relates to an additive composition for a polymer substrate comprising a carrier material, an antimicrobial substance present in an amount of from 1% w/w to 50% w/w. and a food preservative present in amount of from 1% w/w to 75% w/w, wherein the antimicrobial substance is different to the food preservative.