Flexible Pouch Using PCR With GI200 Over 50
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Solution Overview
Problem
The use of post-consumer resin (PCR) in flexible film applications for liquid packaging is challenging due to its inherent variability, which leads to issues such as foul odors and unpleasant tastes when in contact with food, and the need for a pouch that is both leak-free and structurally strong enough to survive the supply chain.
Innovation Solution
A flexible pouch design featuring a first layer structure and a second layer structure, where each layer includes an inner liner and an outer sheath composed of PCR material with a GI200 value greater than 50, and a peripheral seal that extends along the common peripheral edge to seal the layers, ensuring leak-free and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If PCR material is used in flexible film applications, then environmental sustainability is improved, but material variability and quality consistency deteriorate
Solution Approach 1:
The patent specifies a minimum GI200 value of 50 for the PCR material to ensure adequate gel strength and structural integrity. By establishing this quantitative parameter threshold, the invention transforms the variability issue into a controllable specification, ensuring consistent performance while maintaining PCR's environmental benefits.
Solution Approach 2:
The invention uses a multi-layer composite structure where PCR material is combined with other polymeric materials in specific layers. This composite approach allows the PCR to provide environmental sustainability while the other materials compensate for its inherent variability, achieving both ecological and performance goals.
2Productivity
If PCR material is used in food contact applications, then recyclability is improved, but food safety deteriorates due to foul odor and unpleasant taste
Solution Approach 1:
The patent divides the flexible pouch into distinct layers, placing the PCR material in specific layers while using other materials in layers that directly contact the food. This segmentation isolates the PCR's recyclability benefits from direct food contact, preventing odor and taste issues while maintaining recyclability.
Solution Approach 2:
The multi-layer structure acts as an intermediary barrier between the PCR material and the food contents. The other polymeric material layers serve as intermediaries that prevent direct contact between the PCR and food, eliminating harmful odors and tastes while preserving the PCR's recyclability.
3Ease of manufacture
If flexible pouch structure is simplified, then manufacturing ease is improved, but structural integrity and leak prevention deteriorate
Solution Approach 1:
The patent employs a multi-layer flexible film structure where each layer contributes specific properties. The combination of layers creates a composite structure that maintains flexibility and ease of manufacture while providing sufficient structural integrity and leak prevention through the synergistic properties of the layers.
4Ease of operation
If flexible pouch is designed for flexibility, then ease of operation is improved, but structural strength to survive supply chain deteriorates
Solution Approach 1:
The multi-layer composite structure allows different layers to specialize: some layers provide flexibility for ease of operation while others provide structural strength to survive the supply chain. The composite nature enables both contradictory requirements to be satisfied simultaneously through material synergies.
Solution Approach 2:
The patent specifies a minimum GI200 value of 50 for the PCR material, which ensures adequate gel strength and structural integrity. By controlling this parameter, the invention maintains structural strength while preserving the flexibility needed for ease of operation.
Data Source
AI summary
The present disclosure provides a flexible pouch. In an embodiment, the flexible pouch includes a first layer structure and a second layer structure. Each layer structure includes (i) an inner liner and (ii) an outer sheath. The first layer structure is superimposed on the second layer structure such that the inner liners oppose each other. The first layer structure superimposed upon the second layer structure defines a common peripheral edge. Each inner liner is composed of a flexible film of a polymeric material. Each outer sheath is composed of a post-consumer recycle (PCR) polymer material. The PCR polymer material has a GI200 value greater than 50. The flexible pouch includes a peripheral seal. The peripheral seal extends along at least a portion of the common peripheral edge. The peripheral seal seals the first layer structure to the second layer structure.