Atmosphere Control Membrane for Sealed Biological Packaging
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Solution Overview
Problem
Existing atmosphere control systems in shipping containers for respiring biological materials face challenges due to air leaks, requiring a higher oxygen transmission ratio (OTR) and specific gas exchange ratios to maintain optimal packaging atmospheres, which current technologies fail to consistently achieve.
Innovation Solution
The development of atmosphere control members (ACMs) with an OTR of at least 620,000 ml/m2.atm.24 hr and a carbon dioxide to oxygen permeability ratio (R ratio) of at least 4.3, featuring porous substrates and polymeric coatings, along with innovative designs such as folded sheets and one-way valves, to effectively manage gas exchange and maintain desired atmospheric conditions within shipping containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional atmosphere control members are used in shipping containers, then the packaging atmosphere can be controlled to some extent, but air leaks cause the atmospheric pressure to drop below atmospheric pressure and the gas exchange ratio to become unbalanced
Solution Approach 1:
The patent changes the key parameters of the atmosphere control member by specifying an OTR of at least 620,000 ml/m2.atm.24 hr and an R ratio of at least 4.3, which fundamentally alters the gas exchange characteristics to compensate for air leaks and maintain atmospheric pressure balance
Solution Approach 2:
The patent anticipates the harmful effect of air leaks by designing the ACM with excessive gas transmission capacity (OTR ≥ 620,000) that provides a buffer against pressure losses, ensuring the packaging atmosphere remains stable even when container seals fail
2Adaptability or versatility
If the packaging atmosphere is controlled by displacing gases in a sealed container, then the desired atmosphere can be achieved, but this method cannot compensate for air leaks in shipping containers
Solution Approach 1:
The ACM performs self-regulation by automatically adjusting gas exchange rates based on the pressure differential and concentration gradients, maintaining the desired atmosphere without external intervention even when container seals are compromised
Solution Approach 2:
The patent employs dynamic parameter changes in the ACM design (high OTR ≥ 620,000 and specific R ratio ≥ 4.3) that allow the system to adapt to varying seal conditions and maintain atmospheric control reliability despite air leaks
3Stability of the object's composition
If a higher oxygen transmission ratio is used to compensate for air leaks, then atmospheric pressure stability is improved, but the packaging atmosphere may become unbalanced
Solution Approach 1:
The patent precisely controls the R ratio (CO2 permeability/O2 permeability) to be at least 4.3, which balances the gas exchange rates and prevents atmospheric imbalance while maintaining pressure stability through the high OTR
Solution Approach 2:
The ACM is constructed as a composite material system combining a porous substrate with a polymeric coating, where the substrate provides mechanical strength and the coating provides selective gas permeability with the desired OTR and R ratio characteristics
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
These ACMs ensure effective control of oxygen and carbon dioxide levels, maintaining optimal packaging atmospheres despite air leaks, thereby extending the shelf life and quality of respiring biological materials during transportation.
Implementation Method 1
has a permeability to O2 and CO2 such that gas exchange of O2 and CO2 through the ACM produces the desired packaging atmosphere
Data Source
AI summary
Packaging of respiring biological materials, particularly bananas and other fruits, in sealed containers. The containers preferably include a gas-permeable membrane comprising (1) a microporous film, and (2) a polymeric coating on the microporous film. Using appropriate containers and appropriate controlled atmospheres around the container, the respiring materials can be stored and/or ripened under controlled conditions. Bananas can be ripened while they are being transported, or in conventional ripening rooms without opening the containers in which they have been transported. The ripe bananas are less dehydrated and remain in a satisfactory ripened state for longer periods of time. The gas-permeable membrane can preferably take the form of either a “curtain” or “cartridge” and the R ratio of the membrane may be optimized by adjusting the differential pressure across the membrane.