Compostable Multilayer Membrane Oxygen Barrier Structure

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Solution Overview

Problem

Current cartridges for coffee and soluble products do not meet compostability requirements, and compostable barrier layers often require costly processing to achieve adequate oxygen and water barrier properties, which can compromise the freshness and flavor of the products.

Innovation Solution

A compostable multilayer membrane with a structure comprising a first and second compostable barrier layer, a metallization layer, and an intermediate adhesive layer, which provides oxygen and water barrier properties without using cellulosic materials, ensuring compliance with compostability standards and maintaining product freshness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If compostable materials are used for cartridge manufacturing, then environmental sustainability is improved, but oxygen and water barrier properties deteriorate

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidoxygen and water barrier properties

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies composite materials by combining multiple layers with different properties: a compostable barrier layer (PLA or starch-based) provides environmental sustainability, while an aluminum foil layer provides superior oxygen and water barrier properties. The combination creates a multilayer structure that achieves both compostability and effective barrier performance, resolving the contradiction between environmental friendliness and protective functionality.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If cellulosic materials are used for barrier layers, then compostability is improved, but manufacturing costs increase due to costly processing

Engineering Contradiction:

ImprovecompostabilityVSAvoidmanufacturing costs

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent uses composite materials where a thin compostable barrier layer (PLA or starch-based) is combined with an aluminum foil layer. This approach reduces the need for costly processing of thick compostable materials while maintaining compostability credentials. The aluminum layer provides the primary barrier function, allowing the compostable layer to be thinner and less expensive to manufacture.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs thin film structures where the compostable barrier layer is used as a thin coating or layer rather than a thick structure. This reduces material consumption and processing costs while maintaining compostability. The thin film approach allows the compostable material to serve its environmental function without requiring expensive extensive processing.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If aluminum is used for cartridge materials, then oxygen and water barrier properties are improved, but compostability deteriorates

Engineering Contradiction:

Improveoxygen and water barrier propertiesVSAvoidcompostability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite material structure where an aluminum foil layer provides excellent oxygen and water barrier properties, while a compostable polymer layer (PLA or starch-based) provides the compostable outer surface. This multilayer composite allows the aluminum to fulfill its barrier function without preventing the overall structure from being compostable, as the compostable layer protects the aluminum and enables biodegradation.

Inventive Principle:

Principle #40Composite 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 membrane achieves oxygen barrier values of less than 0.1 cc/m2/day/atm, ensuring the preservation of product freshness while meeting compostability requirements, and allows for proper dispensing of pressurized-fluid brewed beverages.

Implementation Method 1

a metallization layer, and an intermediate adhesive layer, which provides oxygen and water barrier properties

Methodology Applied

Scientific EffectMetallization: Deposition (physical)

Data Source

PatentUS11117739B2Compostable multilayer membranes and cartridges using such membranes

Publication Date: 2021.09.14 GOGLIO

AI summary

A compostable multilayer membrane may include: a first barrier layer containing a compostable barrier film; a first metallization layer; an intermediate layer containing at least one adhesive; a second barrier layer containing a compostable barrier film; a layer adjacent to the first barrier layer, on a side opposite to the first metallization layer, the adjacent layer comprising heat-resistant lacquer; a second metallization layer between the intermediate layer and the second barrier layer; and a filter made of nonwoven fabric. The compostable barrier film of the first barrier layer may not be made of cellulosic material. The compostable barrier film of the second barrier layer may not be made of cellulosic material. The compostable multilayer membrane may have an Oxygen Transfer Rate (OTR) value lower than 0.5 cc/m2/day/atm. The filter may be adjacent to the second barrier layer on a side opposite to the intermediate layer.