Recyclable EVOH Barrier Film Packaging With Vacuum Sealing
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Solution Overview
Problem
Existing food packaging methods using multi-layer films are not recyclable, leading to plastic waste and pose challenges in maintaining a germ-free and durable packaging environment.
Innovation Solution
A method utilizing a thermally shrinkable EVOH film with a barrier layer, sealed under negative pressure or with a pressure relief valve, to create a film bag around the object and carrier, ensuring airtight and recyclable packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-layer films (e.g., LDPE/EVOH/PP) are used for packaging, then the packaging provides effective barrier properties against germs, bacteria, and oxygen, but the packaging becomes non-recyclable and generates plastic waste
Solution Approach 1:
The packaging system is segmented into two separate components: a recyclable carrier (tray) and a recyclable film bag. The carrier retains the food items while the film bag provides barrier protection. This segmentation allows each component to be optimized for its specific function while maintaining overall recyclability, eliminating the need for non-recyclable multi-layer composite materials.
Solution Approach 2:
The film bag acts as an intermediary barrier between the food items on the carrier and the external environment. By placing the film bag over the carrier, the system achieves effective barrier properties against germs, bacteria, and oxygen without requiring the carrier itself to be made of complex multi-layer non-recyclable materials.
2Ease of operation
If the carrier projects significantly beyond the object, then the sealing process becomes easier, but the packaging efficiency and material usage deteriorate
Solution Approach 1:
The patent specifies that the carrier should project beyond the object by only 3-15 mm, establishing an optimal parameter range that balances sealing ease with material efficiency. This quantitative parameter optimization ensures sufficient overlap for effective sealing while minimizing excess packaging material and maintaining packaging efficiency.
3Device complexity
If the film bag is sealed without vacuum, then the sealing process is simpler, but the packaging fails to adapt to the carrier and object shape, reducing durability
Solution Approach 1:
A vacuum pump is introduced to create negative pressure inside the film bag during sealing. This pneumatic approach causes the film bag to conform tightly to the shape of the carrier and food items, ensuring complete adaptation and eliminating air pockets. The vacuum sealing process, while adding a pump, uses a straightforward mechanical process that maintains reliability without excessive complexity.
4Reliability
If thermal shrinkage is applied to the film bag, then the packaging becomes more durable and conforming, but air expansion during heating can disrupt the shrinkage process
Solution Approach 1:
The film bag is vacuum-sealed before the thermal shrinkage process begins. This preliminary vacuum action removes most air from the bag, preventing significant air expansion during subsequent heating. By establishing the vacuum condition prior to thermal treatment, the system ensures that the film bag can shrink conformingly to the carrier and food items without disruption from expanding air pockets.
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 achieves airtight, durable, and recyclable packaging that prevents bacterial penetration and atmospheric gas ingress, while maintaining the integrity of the packaging during thermal shrinkage.
Implementation Method 1
difficult or impossible for bacteria and germs to penetrate. Likewise, it can be virtually impervious to atmospheric gases such as oxygen, carbon dioxide, or the like
Implementation Method 2
The film is thermally shrinkable... the barrier film or film bag is heated to shrink the barrier film through thermal action
Implementation Method 3
This can be achieved in several ways... a vacuum pump can be inserted into the not yet fully sealed film bag... to extract air from the film bag or to generate the negative pressure
Implementation Method 4
The film bag is sealed, or the barrier film forms the film bag during sealing, by placing at least two layers of barrier film on top of each other and joining them by thermal welding
Data Source
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AI summary
In one method for packaging an object in a thermally shrinkable barrier film, a carrier with the object on it is completely wrapped in the barrier film. This involves either creating a negative pressure in the film bag and then sealing the film bag with the negative pressure inside. Alternatively, the finished film bag can have a pressure relief valve attached to the barrier film or a vent hole that is sealed hermetically after shrinking. The film bag is sealed by thermally welding at least two superimposed layers of the barrier film together, and then the barrier film is thermally shrinked to tightly fit the film bag against the carrier with the object on it. The barrier film is two-layered with a thin layer of EVOH film in between to ensure recyclability.