High-Density Paper Substrate Oxygen Barrier
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Solution Overview
Problem
There is a need for non-aluminium-foil packaging materials with improved oxygen gas barrier properties, recyclability, and environmental sustainability for packaging oxygen-sensitive products like food and water, as existing materials fail to provide comparable performance and efficiency.
Innovation Solution
A high-density paper substrate made from cellulose fibres with a grammage of 30 to 75 g/m² and a density above 1000 kg/m³, impregnated with polymers like polyvinyl alcohol, ethylene vinyl alcohol, and starch, and coated with gas barrier materials, is used in laminated packaging materials to enhance gas barrier properties and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminium foil is used as gas barrier material, then oxygen gas barrier properties are improved, but recyclability and environmental sustainability deteriorate
Solution Approach 1:
The invention changes the material parameters by replacing aluminium foil with high-density paper substrate (density >1000 kg/m³) impregnated with gas barrier polymers. This parameter change maintains the gas barrier function while improving recyclability, as the paper-based composite can be processed in conventional paper recycling streams unlike aluminium-containing laminates.
Solution Approach 2:
The invention creates a composite material system consisting of high-density paper substrate combined with impregnating polymers (PVOH, EVOH, starch, nanocrystalline cellulose). This composite achieves aluminium-comparable oxygen barrier properties through the synergistic combination of dense paper structure and polymer impregnation, while maintaining compatibility with paper recycling processes.
2Ease of manufacture
If conventional paper substrates are used, then recyclability is maintained, but gas barrier properties deteriorate
Solution Approach 1:
The invention modifies conventional paper substrates by increasing density above 1000 kg/m³ through controlled manufacturing processes and impregnating with gas barrier polymers. This parameter transformation enables the paper to achieve aluminium-competitive oxygen barrier properties (OTR values) while remaining compatible with paper recycling infrastructure.
Solution Approach 2:
The impregnating polymers act as intermediaries that bridge the gap between conventional paper porosity and required gas barrier performance. Polymers like PVOH, EVOH, and nanocrystalline cellulose fill the porous structure of high-density paper, creating a dual-function material that provides both structural integrity and aluminium-level gas barrier properties.
3Reliability
If paper density is increased above 1000 kg/m³, then gas barrier properties are improved, but manufacturing complexity increases
Solution Approach 1:
The invention achieves high density (>1000 kg/m³) through optimized paper manufacturing parameters including fiber selection, pressing conditions, and drying processes. These parameter optimizations create a dense paper substrate that naturally provides improved gas barrier properties while maintaining compatibility with existing paper manufacturing equipment and processes.
Solution Approach 2:
The high-density paper substrate is prepared in advance with optimized density and structure before polymer impregnation. This preliminary action of creating the dense paper matrix simplifies subsequent impregnation processes and ensures consistent gas barrier performance, reducing overall manufacturing complexity compared to attempting to achieve density through multiple post-processing steps.
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 provides effective gas and water vapour barrier properties, maintains package integrity, and supports long-term aseptic storage of liquid foods, while being cost-efficient and environmentally sustainable, with improved recyclability and reduced material waste.
Implementation Method 1
a high-density paper substrate made from cellulose fibres, as a gas-barrier material in a laminated packaging material
Implementation Method 2
the porous network of the cellulose fibres may at least at and beneath the surface of the paper be filled and surrounded by the polymers
Implementation Method 3
the top-side surface of the high-density paper acquired a roughness lower than 100 ml/min Bendtsen, by the calendering operation
Implementation Method 4
the top-side surface of the high-density paper substrate has at least one coating of at least one gas barrier material
Data Source
AI summary
The disclosure relates to the use of a high-density paper substrate made from cellulose fibres, as a gas-barrier material in a laminated packaging material for packaging of oxygen sensitive products, and further to coated such high-density paper substrates for increased gas barrier properties. Also disclosed are laminated packaging materials comprising the high-density paper substrates or coated high-density paper substrates, and packaging containers comprising the laminated packaging material, for packaging of oxygen-sensitive products.