Barrier-Coated Cellulose Substrate for Laminated Packaging

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Solution Overview

Problem

Current packaging materials for oxygen-sensitive products, such as liquid and semi-liquid foods, lack improved gas barrier properties and recyclability, and are not cost-efficient alternatives to aluminum foil-based laminates.

Innovation Solution

A barrier-coated cellulose-based substrate with a ductile base layer pre-coating and a gas barrier coating, applied via dispersion or vapour deposition, providing enhanced gas barrier properties and recyclability, is used in laminated packaging materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum foil is used as the gas barrier layer, then gas barrier properties are improved, but recyclability deteriorates and cost increases

Engineering Contradiction:

Improvegas barrier propertiesVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameters by replacing aluminum foil with organic polymer coatings (EVOH, PVOH, PVDC) that provide comparable gas barrier properties while being recyclable. The coating thickness and composition are optimized to achieve the required oxygen transmission rates without using metal foil

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs thin-film polymer coatings that are cost-effective and suitable for single-use packaging applications. These coatings provide adequate barrier performance for the intended shelf life of packaged products while being more economical and recyclable than aluminum foil

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If aluminum foil is used as the gas barrier layer, then gas barrier properties are improved, but manufacturing cost increases

Engineering Contradiction:

Improvegas barrier propertiesVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent optimizes coating parameters including thickness (nanometer to micrometer range), polymer composition, and application method to achieve cost-effective gas barrier performance. The use of thin-film technology reduces material consumption and manufacturing costs compared to aluminum foil while maintaining required barrier properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs cost-effective polymer coatings suitable for disposable packaging applications. These coatings provide adequate barrier performance for typical product shelf lives at lower material and processing costs than aluminum foil

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If thin gas barrier coating is applied, then material usage is reduced, but barrier properties deteriorate

Engineering Contradiction:

Improvecoating material usageVSAvoidgas barrier properties

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent uses composite coating structures combining multiple polymer layers with different functions. The gas barrier layer (e.g., EVOH, PVOH) is combined with adhesive layers and protective layers to achieve optimal performance. This composite approach allows thin coating thickness while maintaining adequate barrier properties through synergistic material combinations

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes coating thickness parameters within a specific range (nanometer to micrometer) to achieve the right balance between material usage and barrier performance. Advanced coating technologies enable precise thickness control to maximize barrier efficiency per unit thickness

Inventive Principle:

Principle #35Parameter changes

4Reliability

If high-density cellulose substrate is used, then barrier properties are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvebarrier propertiesVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent specifies precise substrate parameters including density (≥900 kg/m³), grammage (30-80 g/m²), and fiber composition to achieve optimal barrier properties. These controlled parameters ensure consistent performance while using conventional papermaking and coating equipment

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 achieves improved gas barrier properties and recyclability, enabling long-term aseptic storage of oxygen-sensitive products while reducing costs compared to aluminum foil-based materials.

Implementation Method 1

a ductile base layer pre-coating, which is applied by means of dispersion coating and subsequent drying, onto a surface of the first side of the cellulose-based substrate

Methodology Applied

Scientific EffectDispersion coating: Dispersion (of waves)

Implementation Method 2

applying at least one gas barrier coating of at least one gas barrier material to a total thickness from 2 to 5000 nm

Methodology Applied

Scientific EffectVapour deposition: Physical Vapour Deposition

Data Source

PatentUS20250019900A1Barrier-coated cellulose-based substrate for laminated packaging material

Publication Date: 2025.01.16 TETRA LAVAL HOLDINGS & FINANCE SA

AI summary

The present invention relates to a barrier-coated cellulose-based substrate and to a method of manufacturing such cellulose-based substrates, by dispersion coating of a ductile base layer pre-coating and subsequent dispersion coating of a gas barrier composition and/or vapour deposition coating of a barrier deposition coating.