Non-foil Laminated Packaging Material with Graphene Oxide Barrier
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Solution Overview
Problem
The existing packaging materials for liquid food cartons, which rely on aluminum foil for gas barrier properties and heat sealing, are not sustainable due to aluminum's non-renewable nature and recyclability issues.
Innovation Solution
A non-foil laminated packaging material is developed, comprising a barrier substrate with a vapour-deposited metal layer and a layer of reduced graphene oxide adjacent to the metal layer, which is suitable for induction heat sealing and provides improved thermomechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum foil is used in packaging material, then gas barrier properties and heat sealing capability are improved, but sustainability and recyclability deteriorate
Solution Approach 1:
The patent applies composite materials by combining a vapour-deposited metal layer (providing gas barrier properties) with a polymer matrix and functional additives (providing heat sealing capability). This composite structure replaces traditional aluminum foil while maintaining the necessary barrier and sealing functions through the synergistic combination of different materials with complementary properties.
Solution Approach 2:
The patent changes the physical and chemical parameters of the packaging material by using a vapour-deposited metal layer with controlled thickness and composition, combined with specific polymer matrices and functional additives. These parameter changes enable the material to achieve both gas barrier properties and heat sealing capability without relying on aluminum foil, thereby improving sustainability.
2Manufacturing precision
If aluminum foil is used for heat sealing, then seal quality is improved, but power endurance during induction heat sealing deteriorates
Solution Approach 1:
The patent changes the electromagnetic and thermal parameters of the sealing layer by incorporating a vapour-deposited metal layer with optimized thickness and conductivity, combined with polymer matrices and functional additives. These parameter changes enable the material to achieve both high seal quality and improved power endurance during induction heat sealing by balancing electromagnetic induction efficiency with thermal energy distribution.
Solution Approach 2:
The patent uses composite materials in the heat seal layer, combining vapour-deposited metal (for electromagnetic induction and seal quality) with polymer matrices and functional additives (for power endurance and thermal stability). This composite structure allows the material to maintain high seal quality while withstanding prolonged induction heating without excessive power consumption or material degradation.
3Object-affected harmful factors
If aluminum foil is replaced with sustainable materials, then recyclability is improved, but barrier properties may deteriorate
Solution Approach 1:
The patent applies composite materials by combining a vapour-deposited metal layer (providing gas barrier properties) with a polymer matrix and functional additives. This composite structure replaces traditional aluminum foil while maintaining the necessary barrier and sealing functions through the synergistic combination of different materials with complementary properties.
Solution Approach 2:
The patent applies local quality by concentrating the gas barrier function in the vapour-deposited metal layer while the polymer matrix and functional additives provide other necessary functions such as heat sealing, mechanical strength, and flexibility. This localized functional distribution allows each layer to optimize its specific role, maintaining high barrier properties while improving overall sustainability and recyclability.
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 solution achieves high seal quality and power endurance during induction heat sealing, maintaining the barrier properties necessary for long-term storage and aseptic packaging, while being more sustainable and recyclable compared to traditional aluminum-based materials.
Implementation Method 1
a barrier material formed of a barrier substrate layer bearing a vapour-deposited metal layer
Implementation Method 2
The technique of induction welding is based on Faraday's law, by which an alternating magnetic field generated around a conductor is capable of inducing an electrical current in another conductor placed in close proximity (workpiece). Heat is then generated in the workpiece due to Joule effect.
Implementation Method 3
Heat is then generated in the workpiece due to Joule effect
Data Source
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AI summary
A non-foil laminated packaging material for heat sealing into packages for liquid or semi-liquid food products comprises: - a barrier material formed of a barrier substrate layer bearing a vapour-deposited metal layer and a layer of optionally reduced graphene oxide immediately adjacent to the vapour-deposited metal layer; and - a heat seal layer. A method of making the laminated packaging material, a packaging container, and a method of forming a packaging container from the laminated packaging material are also described.