Biodegradable Polymer Material Oxygen Barrier
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Solution Overview
Problem
Existing biodegradable and compostable polymer materials for packaging, particularly coffee capsules, lack effective barrier properties, leading to reduced shelf life and flavor integrity due to gas, vapor, and aroma permeability, while also being costly and difficult to recycle.
Innovation Solution
A biodegradable polymer material composed of 30-70% biodegradable base polymer and 70-30% biodegradable barrier material, preferably polyvinyl alcohol polymers, with improved processing stability and reduced costs, allowing for efficient injection molding and maintaining mechanical strength and low density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating or multi-layer structure is applied to increase barrier properties, then shelf life and quality are improved, but recycling and compostability are lost and manufacturing effort increases
Solution Approach 1:
The invention combines the barrier material and base polymer into a single homogeneous biodegradable polymer composition, eliminating the need for separate coating or multi-layer structures. This merging approach maintains barrier properties while preserving compostability and reducing manufacturing complexity.
Solution Approach 2:
The invention uses a composite polymer material consisting of a base polymer and a barrier material in specific ratios (30-70% base polymer and 70-30% barrier material). This composite structure provides both barrier properties and biodegradability without requiring separate layers or coatings.
2Reliability
If aluminum and polymer laminate is used to achieve good barrier properties, then shelf life is extended, but recycling becomes time-consuming and production steps increase
Solution Approach 1:
The invention extracts the aluminum layer from the laminate structure and replaces it with a biodegradable barrier material. This removal of aluminum simplifies the material composition to a single biodegradable polymer system, eliminating the need for separation steps in recycling while maintaining barrier properties.
Solution Approach 2:
The invention changes the material composition parameters by using specific ratios of base polymer and barrier material (30-70% and 70-30% respectively). This parameter optimization achieves the desired barrier properties while maintaining biodegradability and simplifying production.
3Reliability
If barrier material is added to improve oxygen permeability, then shelf life is extended, but mechanical properties and processability may deteriorate
Solution Approach 1:
The invention optimizes the composition parameters by specifying that the base polymer content should be 30-70% and barrier material 70-30%. This parameter range balances the competing requirements of barrier properties and mechanical strength, ensuring both are satisfied within the defined composition window.
Solution Approach 2:
The invention assigns different functional roles to different components within the polymer composition. The base polymer provides mechanical strength and processability, while the barrier material provides oxygen and aroma barrier properties. This local functional differentiation allows each component to excel at its specific function while working together as a unified material.
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 polymer material achieves significantly reduced oxygen permeability, extending the shelf life of coffee powder and maintaining mechanical stability, while being cost-effective and recyclable, thus addressing the limitations of existing materials.
Implementation Method 1
barrier properties mean the non-existent or very low permeability (diffusion) of gases (e.g. oxygen)
Data Source
AI summary
The invention relates to a polymer material comprising 30-70% by weight, preferably 35-65% by weight, particularly preferably 40-60% by weight, of a base polymer that is biodegradable according to ISO 14855, and comprising 70-30% by weight, preferably 65-35%, particularly preferably 60-40%, of a barrier material that is biodegradable according to ISO 14855. According to the invention, the ratio of the oxygen permeability (according to ASTM D3985) of the base polymer to the oxygen permeability of the polymer material is greater than 2, preferably greater than 2.5.