Embossed Packaging Material Tactile Pattern Lamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging materials for liquid foods lack effective protruding tactile patterns on the outer side, which can be damaged during embossing, compromising the integrity of the package, especially when aluminum foil is used.
Innovation Solution
Embossing is performed on the core material layer before lamination to create protruding features, which are then temporarily flattened during lamination, and later restored by increasing temperature, humidity, or pressure to regain their initial height, ensuring the tactile pattern is maintained without damaging the inner laminate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossing is performed after lamination to create protruding tactile patterns, then the tactile pattern can be formed on the outer side of the packaging material, but the inner laminate layers (especially aluminum foil) may be damaged during embossing
Solution Approach 1:
The embossing is performed on the core material layer before lamination with the inner laminate layers. This preliminary action creates the tactile pattern on the core layer without exposing the fragile aluminum foil to the high pressure of embossing, thus preventing damage to the inner laminate layers while still achieving the desired protruding pattern effect
Solution Approach 2:
Instead of the conventional approach of laminating first and then embossing, the invention inverts the sequence by embossing first and then laminating. This reversal protects the aluminum foil from embossing damage while maintaining the tactile pattern functionality on the outer surface
2Ease of manufacture
If embossing is performed after lamination, then the tactile pattern can be created, but the aluminum foil barrier layer may be damaged compromising package integrity
Solution Approach 1:
The embossing operation is performed as a preliminary action on the core material layer before the aluminum foil barrier layer is laminated. This ensures the tactile pattern is created without exposing the aluminum foil to embossing pressure, eliminating the harmful effect of foil damage
Solution Approach 2:
The core material layer acts as an intermediary that absorbs the embossing pressure and protects the aluminum foil barrier layer. By performing embossing on the core layer first, the aluminum foil is shielded from direct contact with the embossing dies, preventing barrier damage
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 method allows for the creation of packaging materials with protruding tactile patterns on the outer side that are durable and effective in indicating gripping areas, while maintaining the integrity of the inner laminate layers, enhancing user handling and package recognition.
Implementation Method 1
laminating at least one layer to the inner side of said embossed core material layer such that the height of the embossed features is temporarily reduced to a minimum height
Implementation Method 2
the height of the embossed features is increased relative its minimum height by one or more steps of action selected from increasing the temperature in the packaging material, increasing the humidity in the packaging material, and increasing the pressure acting on the packaging material
Data Source
AI summary
A method for producing a packaging material comprises providing a core material layer of fibre-based material having an inner side and an outer side, embossing the core material layer for forming embossed features having an initial height, the embossed features protruding from the outer side of the core material layer to later form a tactile pattern on a side of the package to be formed by the packaging material, and laminating at least one layer to the inner side of the embossed core material layer such that the height of the embossed features is temporarily reduced to a minimum height.