Multi-Layer Container Barrier With Tapered Oxygen Layer
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Solution Overview
Problem
Current containers lack an effective and clear oxygen barrier layer, particularly in low-cost, polymeric containers, which are essential for storing oxygen-sensitive products.
Innovation Solution
A multi-layer barrier preform for containers is designed with an oxygen barrier layer encapsulated between the inner and outer portions of the container, tapered to be closest to the inner surface at the bottom portion and furthest from the inner surface near the support flange, and confined to the inner half of the container wall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an oxygen barrier layer is added to the container, then oxygen permeability is reduced, but the container may become less clear or more complex
Solution Approach 1:
The oxygen barrier layer is positioned only in the inner portion of the container wall, specifically in the region where oxygen permeation is most critical for product protection. This localized placement provides effective oxygen barrier functionality while minimizing the barrier layer's impact on the overall container clarity, as the barrier layer is confined to a specific zone rather than being distributed throughout the entire wall structure.
Solution Approach 2:
The container employs a multi-layer composite structure combining a base layer and an oxygen barrier layer. The base layer provides structural integrity and clarity, while the oxygen barrier layer (comprising polyester, copolymer ether, and oxidation catalyst) provides oxygen protection. This composite approach allows each material to optimize its specific function without compromising the other.
2Object-affected harmful factors
If the oxygen barrier layer is made thicker to improve barrier effectiveness, then oxygen permeability decreases, but the container wall becomes more complex and may affect clarity
Solution Approach 1:
The oxygen barrier layer is confined to the inner half of the total container wall thickness, specifically positioned in the inner portion rather than extending through the entire wall. This localized confinement provides sufficient oxygen barrier protection while maintaining a relatively simple wall structure that preserves clarity. The barrier layer thickness is optimized to be less than the inner and outer portion thicknesses, avoiding excessive complexity.
Solution Approach 2:
The oxygen barrier layer extends partially through the wall thickness (confined to the inner half) rather than fully through the entire wall. This partial action is sufficient to achieve the desired oxygen barrier effect while avoiding the complexity and potential clarity issues that would result from a full-thickness barrier layer. The tapering design ensures the barrier is present where needed without excessive material usage.
3Object-affected harmful factors
If the oxygen barrier layer is positioned closer to the inner surface for better protection, then oxygen barrier effectiveness improves, but the outer surface may be compromised
Solution Approach 1:
The oxygen barrier layer is strategically positioned in the inner portion of the wall, closest to the inner surface where oxygen permeation occurs, while the outer surface maintains the base layer structure for structural integrity. This spatial separation allows the barrier layer to provide maximum oxygen protection without compromising the strength and surface quality of the outer container wall.
Solution Approach 2:
The container wall is segmented into distinct functional zones: an inner portion containing the oxygen barrier layer for oxygen protection, and an outer portion maintaining the base layer structure for structural strength. This segmentation allows each zone to optimize its specific function independently, with the barrier layer confined to the inner region and the outer surface preserving its structural role.
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 effectively reduces oxygen absorption by the container, maintaining a low oxygen permeability and ensuring the container remains clear and haze-free, suitable for storing oxygen-sensitive products over a 24-month shelf life.
Implementation Method 1
an oxygen barrier layer encapsulated between the inner portion and the outer portion
Implementation Method 2
The oxygen barrier layer includes an oxygen scavenger and polyethylene terephthalate (PET) having a cobalt catalyst
Data Source
AI summary
A container including a finish, a body, and a base. The finish includes a top sealing surface, threads, and a support flange. The top sealing surface includes only a base layer. The body and the base each include an inner portion made of the base layer, an outer portion made of the base layer, and an oxygen barrier layer between the inner portion and the outer portion.