Card-Based Package Barrier Coating for Recyclable Sensitive Materials

Solution Overview

Problem

Existing card-based packages for sensitive materials, such as powdered infant nutrition, lack adequate light, oxygen, and water vapor barriers, and are difficult to recycle effectively due to laminates with non-paper-based layers, compromising their environmental impact and recyclability.

Innovation Solution

A card-based package with a container and lid structure formed from predominantly cellulose materials, incorporating a thin inner hygienic layer and optional barrier layers, ensuring oxygen and water vapor transmission rates below 0.5 cc/m2/day and 0.5 g/m2/day respectively, with a recyclable design that maintains sterility and hygiene, and includes a collar portion for additional functionalities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If card-based materials are used to substitute petroleum-based packaging, then environmental impact is reduced and recyclability is improved, but barrier properties (light, oxygen, water vapor) are insufficient

Engineering Contradiction:

Improveenvironmental impactVSAvoidbarrier properties

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies composite materials by combining card-based material with a biodegradable barrier coating layer. The card material provides structural integrity and recyclability, while the barrier coating layer (composed of biodegradable polymers, waxes, or oils) provides the necessary light, oxygen, and water vapor barrier properties. This composite structure resolves the contradiction by achieving both environmental friendliness and adequate barrier performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the parameters of the card-based material by applying surface treatments and barrier coatings that modify its permeability characteristics. Through controlling the thickness, composition, and application method of the barrier layer, the patent achieves the required transmission rates (Oxygen Transmission Rate below 0.5 cc/m2/day, Water Vapor Transmission Rate below 0.5 g/m2/day) while maintaining the base material's biodegradability.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If laminates with non-paper-based layers are used to achieve barrier properties, then protection is improved, but recyclability is compromised

Engineering Contradiction:

Improvebarrier propertiesVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material composition parameters by replacing traditional petroleum-based barrier layers with biodegradable alternatives such as plant-based polymers, waxes, or oils. These materials can be applied as thin coatings that provide adequate barrier properties while being compatible with paper recycling processes, thus resolving the contradiction between protection and recyclability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent enables the barrier layer to be discarded with the paper material through biodegradation or pulping processes, rather than requiring separation and specialized recycling streams. The biodegradable coating breaks down during conventional paper recycling, allowing the barrier function to be recovered through reapplication on recycled paper, thus maintaining recyclability while providing protection.

Inventive Principle:

Principle #34Discarding and recovering

3Object-affected harmful factors

If box structures with re-closable lids are used, then economy and environmental friendliness are improved, but barrier properties and closure adequacy are insufficient

Engineering Contradiction:

Improveenvironmental impactVSAvoidclosure adequacy

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies composite materials by combining card-based material with a biodegradable barrier coating layer. The card material provides structural integrity and recyclability, while the barrier coating layer (composed of biodegradable polymers, waxes, or oils) provides the necessary light, oxygen, and water vapor barrier properties. This composite structure resolves the contradiction by achieving both environmental friendliness and adequate barrier performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the parameters of the card-based material by applying surface treatments and barrier coatings that modify its permeability characteristics. Through controlling the thickness, composition, and application method of the barrier layer, the patent achieves the required transmission rates (Oxygen Transmission Rate below 0.5 cc/m2/day, Water Vapor Transmission Rate below 0.5 g/m2/day) while maintaining the base material's biodegradability.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250229939A1Card Based Package for Sensitive Materials

Publication Date: 2025.07.17 NV NUTRICIA

AI summary

A card-based package for sensitive food products, comprises a container portion defining an interior space with a base and a sidewall extending to an upper peripheral edge for receiving a removable seal for hermetically sealing the container portion prior to use. The package further comprises a lid structure, that can open and close to allow selective access to the interior space after removal of the seal. The container portion and the lid structure are both formed of card-based material and at least the container portion has light, oxygen, and water vapour barrier properties sufficient for storage of the product for a period exceeding 24 months.