Cardboard Drinking Cups with Crosslinked Polysiloxane Barrier
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Solution Overview
Problem
Conventional barrier coatings for drinking cups are not cost-efficient, non-biodegradable, and recyclable, and they limit printability and are not transparent, making it difficult to maintain the visibility of print images and provide adequate barrier function.
Innovation Solution
A multilayer cardboard composition for drinking cups, comprising one or more crosslinked polysiloxane layers, a pigment coating or barrier coating layer, a fiber-based substrate layer, and a printed layer, where the crosslinked polysiloxane layers face the interior of the cup, providing a transparent and durable barrier while reducing the content of polyolefins and synthetic organic polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyolefin barrier coatings are used, then barrier properties against liquids and aroma are improved, but cost-efficiency deteriorates due to extra handling and converting steps
Solution Approach 1:
The patent combines the barrier coating function with the printing layer by incorporating barrier-forming pigments (clay, calcium carbonate) and binders directly into the printing ink composition. This integration eliminates the need for separate barrier coating applications and reduces the number of production steps, thereby improving cost-efficiency while maintaining effective barrier properties against liquids and aroma.
Solution Approach 2:
The printing layer is designed to serve multiple functions simultaneously: it provides barrier protection against liquids and aroma, enables printability of the substrate, and offers mechanical protection. By making the printing layer multi-functional, the patent eliminates the need for separate dedicated barrier coating layers, reducing manufacturing complexity and cost.
2Reliability
If conventional barrier coatings are used, then barrier function is improved, but biodegradability and recyclability deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the barrier coating by using natural, biodegradable materials such as plant-based polymers (starch, cellulose, chitosan), natural waxes (beeswax, carnauba wax), and mineral pigments instead of synthetic polyolefins. These material substitutions maintain barrier functionality while improving biodegradability and recyclability, addressing environmental concerns.
3Reliability
If conventional barrier coatings are used, then barrier properties are improved, but printability deteriorates due to surface limitations
Solution Approach 1:
The patent merges the barrier coating function with the printing layer by incorporating barrier-forming pigments and binders into the printing ink composition. This integration ensures that the printing surface itself provides barrier protection, eliminating conflicts between barrier functionality and printability that arise with separate coating layers.
4Reliability
If conventional barrier coatings are used, then barrier function is improved, but transparency deteriorates making print images invisible
Solution Approach 1:
The patent applies local quality by using transparent or translucent barrier-forming materials such as clear plant-based polymer coatings, natural waxes, and transparent mineral pigments. These materials provide barrier protection while maintaining optical transparency, allowing print images to remain visible through the coating layer.
5Reliability
If high amounts of barrier materials are used, then barrier properties are improved, but the amount of synthetic organic polymers increases
Solution Approach 1:
The patent changes the material composition parameters by substituting synthetic organic polymers with natural, biodegradable alternatives including plant-based polymers (starch, cellulose, chitosan), natural waxes, and mineral pigments. This substitution reduces the quantity of synthetic organic polymers while maintaining effective barrier properties through the use of environmentally friendly materials.
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 multilayer cardboard composition achieves a balance of mechanical strength, deep-temperature properties, and recyclability, while ensuring the visibility of print images and providing an effective barrier against liquids and moisture, thus addressing the drawbacks of conventional coatings.
Implementation Method 1
one or more crosslinked polysiloxane layers [A] having a total area weight, determined according to EN ISO 536, within the range of from 0.1 to 50 g·m−2
Implementation Method 2
The sol-gel process is a known method for producing layers of solid materials from small molecules. The process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network (or gel) of network polymers.
Implementation Method 3
The process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network (or gel) of network polymers. In particular, the colloidal solution is formed that then gradually evolves towards the formation of a gel-like diphasic system containing both a liquid phase and solid phase.
Implementation Method 4
In consequences, print images are conventionally applied onto the layers of the barrier materials and then overcoated with suitable transparent materials in order to maintain visibility of the print images
Data Source
AI summary
The invention relates to drinking cups comprising a sidewall that is composed of a multilayer cardboard comprising one or more crosslinked polysiloxane layers [A]; a pigment coating or barrier coating layer [B]; a fiber based substrate layer [C]; optionally, a pigment coating layer [D]; a printed layer [E] comprising a printed image and/or decoration; and optionally, one or more crosslinked polysiloxane layers [F]. The multilayer cardboard preferably has a Cobb 600 value determined according to EN ISO 535 of at least 0.2 g·m2. Preferably, the multilayer cardboard has a total content of polyolefins of at most 5.0 wt.-%, relative to the total weight of the multilayer cardboard.