Gradient C=O Adhesion Layer for Food Container Laminates
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Solution Overview
Problem
Conventional food containers made of glass jars and tins are cumbersome, expensive, and pose safety risks due to their shape, weight, and the need for additional labeling, while existing laminates require expensive adhesion-promoting layers for sterility and impermeability.
Innovation Solution
A sheet-like composite laminate with a specific layer sequence including an outer polymer layer, carrying layer, barrier layer, adhesion-promoting layer, and inner polymer layer, where the adhesion-promoting layer has distinct C=O group absorption maxima to ensure strong adhesion and impermeability without the need for expensive functionalized polyolefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional glass jars and tins are used for food storage, then durability and sterility are improved, but weight, cost, and complexity increase
Solution Approach 1:
The patent changes the material parameters by transitioning from heavy glass and metal to lightweight polymer layers, while maintaining protective functions through specific layer composition and adhesion-promoting layer design with gradient C=O group distribution
Solution Approach 2:
The patent employs a composite laminate structure consisting of multiple polymer layers (inner polymer layer, barrier layer, outer polymer layer) with an adhesion-promoting layer in between, combining the advantages of different materials to achieve both lightweight properties and durability/sterility
2Strength
If functionalized polyolefins with high C=O content are used in the adhesion-promoting layer to ensure strong adhesion, then adhesion strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by creating a gradient distribution of C=O groups within the adhesion-promoting layer: the outer surface (contacting barrier layer) has high C=O content for strong adhesion, while the inner surface (contacting inner polymer layer) has lower C=O content, reducing material cost while maintaining adhesion performance
Solution Approach 2:
The patent changes the chemical composition parameter by using a gradient of C=O group content (1-10% at outer surface, 0.1-5% at inner surface) rather than uniform high C=O content throughout, achieving cost-effective adhesion
3Strength
If the adhesion-promoting layer has uniform high C=O group content throughout, then adhesion to barrier layer is improved, but impermeability and sterility decrease
Solution Approach 1:
The patent applies local quality by spatially differentiating the C=O group content within the adhesion-promoting layer: high C=O content (1-10%) at the outer surface for barrier layer adhesion, and low C=O content (0.1-5%) at the inner surface for inner polymer layer adhesion, ensuring both adhesion and impermeability/sterility
Solution Approach 2:
The patent creates a gradient structure that copies the functional requirements of different interfaces: the outer surface mimics high-adhesion needs, while the inner surface mimics low-permeability needs, optimizing both functions within a single layer
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 laminate provides a cost-effective, lightweight, and stable food container with improved durability for fatty and acidic foods, capable of easy folding and production, while maintaining high tightness and sterility.
Implementation Method 1
the additional adhesion-promoting layer is intended to establish a fixed bond with the barrier layer, for example by forming chemical bonds
Implementation Method 2
functionalised polyolefins which have been obtained by co-polymerisation of ethylene with acrylic acid, acrylates, acrylate derivatives or double-bonded carboxylic anhydrides
Data Source
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AI summary
The invention relates to a sheet-like composite,comprising as layers of a layer sequence: a) an outer polymer layer, b) a carrying layer following the outer polymer layer, c) a barrier layer following the carrying layer, d) an adhesion-promoting layer following the barrier layer, and e) an inner polymer layer following the adhesion-promoting layer; wherein the adhesion-promoting layer comprises an outer surface of the adhesion-promoting layer and an inner surface of the adhesion-promoting layer; wherein the outer surface of the adhesion-promoting layer i) is adjacent to the barrier layer, and ii) is characterised by a first C=O group absorption maximum; wherein the inner surface of the adhesion-promoting layer A) is adjacent to the inner polymer layer, B) is characterised by a second C=O group absorption maximum, and C) has a first distance to the outer surface of the adhesion-promoting layer; wherein the first C=O group absorption maximum is higher than the second C=O group absorption maximum. The invention further relates to a process for manufacturing a sheet-like composite; a sheet-like composite, obtainable by the process; a container precursor; a process for producing a container precursor; a container precursor obtainable by the process; a container; a process for producing a container; a container obtainable by the process; a use of the sheet-like composite; and a use of the container.