CTMP Multi-Ply Tube Packaging Delamination Resistance
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Solution Overview
Problem
Existing tube packaging for personal care products, particularly water-in-oil (W/O) and oil-in-water (O/W) emulsions, faces challenges with delamination of multi-ply paperboard layers during thermal sealing, leading to potential leakage and compromised barrier properties, as well as limited formability and interply bond strength.
Innovation Solution
A multi-ply fiber-based tube container made from a paperboard substrate comprising chemi-thermal mechanical pulp (CTMP) with a specific ply structure and bonding process, which reduces thermal conductivity and eliminates the need for interply adhesives like starch, enhancing ply bonding and resistance to delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-ply paperboard is used for tube packaging, then barrier properties are improved, but delamination of plies occurs during thermal sealing
Solution Approach 1:
A plastic layer is introduced as an intermediary between the paperboard plies. This plastic layer acts as a thermal barrier that prevents direct heat transfer to the paperboard during thermal sealing, thereby preventing steam formation and delamination while maintaining the barrier properties of the multi-ply structure
Solution Approach 2:
The packaging structure is designed as a composite material system combining paperboard plies with a plastic layer. This composite structure leverages the barrier properties of paperboard while the plastic component provides thermal protection during sealing, preventing delamination and maintaining structural integrity
2Strength
If thermal sealing is applied to seal the tube body, then sealing strength is improved, but steam formation and blistering occur
Solution Approach 1:
The plastic layer serves as a thermal intermediary that absorbs and distributes heat during sealing, preventing direct thermal damage to the paperboard. This allows effective sealing while preventing steam formation and blistering in the paperboard structure
Solution Approach 2:
The thermal properties of the packaging structure are modified by introducing the plastic layer, which changes the heat transfer parameters during sealing. This allows the sealing process to proceed at temperatures that effectively seal the tube body without causing thermal damage or steam formation in the paperboard
3Ease of operation
If creasing is applied to facilitate folding, then formability is improved, but barrier properties deteriorate
Solution Approach 1:
The packaging structure is segmented into distinct functional layers: the paperboard plies provide barrier properties while the plastic layer provides flexibility and formability. This segmentation allows each layer to perform its specific function independently, with the plastic layer accommodating folds and creases without compromising the barrier integrity of the paperboard
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 provides a flexible yet rigid container with improved resistance to delamination, maintaining barrier properties and formability, reducing the risk of steam formation and blistering, while ensuring the container's structural integrity and usability.
Implementation Method 1
the fiber based substrate comprises CTMP... decreases the thermal conductivity, whereby less heat from the sealing of plastic components
Implementation Method 2
At thermal sealing of a shoulder to a tube body made from multiply paperboard, heat is transferred to inner plies of the multiply structure. This may cause steam formation
Data Source
AI summary
The invention discloses a container for the packaging of compositions comprising water water-in-oil (W/O) emulsions and/or oil-in-water (O/W) emulsions, which container comprises a tube-formed body made from a paperboard comprising a fiber based substrate comprising a first ply forming a back ply, a second ply forming a top ply and a third ply forming at least one middle ply, wherein the fiber based substrate comprises CTMP. The compositions comprising W/O or O/W emulsions may be semi-solid compositions. The invention solves the problem of delamination of the multi-ply board connected to prior art solutions. In addition, the container provides the specific barriers needed to pack compositions comprising W/O- or O/W-emulsions. It further provides the required flexibility yet rigidity to be used in such tube-formed containers.