Foam-Formed Cellulosic Fibre-Material Packaging
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Solution Overview
Problem
Current packaging materials for liquid foods, such as Tetra Brik Aseptic, rely on thick aluminum foil for gas barrier properties, which is costly, and reducing the thickness of cellulose-based bulk layers compromises mechanical strength and integrity.
Innovation Solution
A method for manufacturing foam-formed cellulosic fibre-material by adding coarse cellulose fibres and a cellulose reinforcement fraction to an aqueous foam, distributing it onto a substrate, and reducing water content, resulting in a material with improved delamination strength and z-directional compression resistance at lower densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of cellulose-based bulk layers is reduced to lower density, then material costs decrease, but mechanical strength and integrity are compromised
Solution Approach 1:
The patent applies composite materials by combining coarse cellulosic fibres (85-97 wt%) with a cellulose reinforcement fraction (3-15 wt%, specifically heavily refined fibres with SR°90). This composite structure enables the foam-formed material to achieve adequate mechanical strength and delamination resistance at reduced densities of 200-450 kg/m3, resolving the contradiction between lowering material quantity/cost and maintaining mechanical integrity
Solution Approach 2:
The patent changes the physical and chemical parameters of the cellulosic material by using heavily refined fibres with specific SR°90 characteristics and controlling the foam formation process. This parameter optimization allows the material to achieve enhanced mechanical properties including delamination strength of at least 100 J/m2 and compression resistance at lower densities, addressing the strength-density trade-off
2Quantity of substance
If coarse cellulosic fibres are used to reduce density, then material costs decrease, but delamination strength is insufficient
Solution Approach 1:
The patent creates a composite fibre system where coarse cellulosic fibres (providing bulk and low density) are combined with a cellulose reinforcement fraction of heavily refined fibres (providing bonding and delamination strength). This composite approach achieves delamination strength of at least 100 J/m2 while maintaining density of 200-450 kg/m3, resolving the contradiction between using low-density materials and achieving adequate delamination resistance
Solution Approach 2:
The patent applies local quality by having different fibre components perform different functions: coarse fibres (85-97 wt%) provide bulk structure and low density, while the heavily refined reinforcement fraction (3-15 wt% with SR°90) provides localized bonding zones that enhance delamination strength. This functional differentiation resolves the contradiction between overall low density and localized strength requirements
3Reliability
If aluminium foil is used for gas barrier properties, then barrier performance is superior, but packaging material costs increase
Solution Approach 1:
The patent replaces expensive aluminium foil with a cost-effective cellulosic foam-formed material that provides adequate gas barrier properties for disposable packaging applications. The use of low-density cellulosic fibres (200-450 kg/m3) with reinforcement fraction creates a sustainable, biodegradable alternative that reduces material costs while maintaining functional performance for single-use packaging
Solution Approach 2:
The patent changes the material composition parameters by incorporating a cellulose reinforcement fraction with specific SR°90 characteristics that enhances barrier properties. This parameter optimization allows the cellulosic material to achieve improved gas barrier performance comparable to aluminium foil alternatives, reducing packaging material costs while maintaining reliability for food packaging applications
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 produces a packaging material with enhanced mechanical properties, including delamination strength and compression resistance, while maintaining low density, thus reducing material costs and maintaining the integrity of the packaging.
Implementation Method 1
providing an aqueous foam comprising a gas dispersed as bubbles in an aqueous phase
Implementation Method 2
wherein said aqueous phase comprises a surfactant
Implementation Method 3
reducing the amount of water in the distributed fibrous foam composition to obtain the foam-formed cellulosic fibre-material
Data Source
AI summary
The invention relates to a method for manufacturing a foam-formed cellulosic fibre-material comprising coarse cellulosic fibres a cellulose reinforcement fraction. Furthermore, the invention relates to a foam-formed cellulosic fibre-material, a cellulose bulk sheet for a packaging material and a laminated packaging material comprising the foam-formed cellulosic fibre-material.