Moulded Cellulose Beverage Capsule Liner Without Tie Layers
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Solution Overview
Problem
Current beverage capsules made of moulded pulp with barrier liners face challenges in biodegradability and manufacturing complexity due to the use of non-biodegradable tie layers and multiple layers with varying thermal properties, which complicates the manufacturing process.
Innovation Solution
A three-layer biodegradable barrier liner comprising an outermost adhesive layer, a middle barrier layer grafted with maleic anhydride, and an innermost structural layer, made of biodegradable polymers, which eliminates the need for tie layers and ensures adhesion to the pulp body, providing a moisture and oxygen barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers with varying thermal properties are used in the barrier liner, then barrier properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts and eliminates the tie layer from the multilayer barrier liner structure. By removing this intermediate layer with different thermal properties, the manufacturing process is simplified while maintaining the essential barrier properties through the remaining layers with controlled thickness and material composition
Solution Approach 2:
The patent uses composite material structures where layers are directly bonded without tie layers. The composite design employs materials with complementary properties that achieve effective barrier performance against oxygen and moisture while allowing direct processing of the layer stack
2Stability of the object's composition
If non-biodegradable tie layers are used in the barrier liner, then adhesion between layers is improved, but biodegradability deteriorates
Solution Approach 1:
The patent changes the chemical and physical parameters of the barrier liner materials to use only biodegradable polymers. By adjusting material composition, thickness, and bonding characteristics, effective adhesion between layers is achieved while ensuring complete biodegradability of the entire structure
Solution Approach 2:
The patent creates a composite structure using multiple biodegradable polymer layers that are directly bonded. The composite design achieves interlayer adhesion through compatible material selection and processing conditions, eliminating the need for non-biodegradable tie layers while maintaining structural integrity
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 results in a fully biodegradable capsule with improved manufacturing simplicity and effective barrier properties, ensuring homogenous application across the surface and reducing environmental impact.
Implementation Method 1
an organic middle barrier layer comprising a butenediol vinyl alcohol copolymer (BVOH) grafted with maleic anhydride
Implementation Method 2
an outermost organic adhesive layer for attaching the liner to the moulded cellulose pulp
Data Source
AI summary
A packaging item includes a body made of rigid or semi-rigid moulded cellulose pulp, and a multilayer film liner attached to the inner surface of the cellulose pulp body. The multilayer film liner includes, from outside to inside, a biodegradable outermost organic adhesive layer for attaching the multilayer film liner to the moulded cellulose pulp, an organic middle barrier layer including a modified alcohol-based polymer (BVOH), and an innermost biodegradable organic structural layer.