IML Packaging with Oxygen Scavenger and Barrier Film
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Solution Overview
Problem
Existing packaging articles for food products face challenges in achieving a balance between design freedom, puncture resistance, and effective oxygen barrier properties, with polypropylene not providing satisfactory oxygen permeability, and oxygen scavengers risking premature activation during storage.
Innovation Solution
A packaging article is developed using a method where an oxygen-scavenging material is embedded within a polypropylene structure through In-Mould-Labelling technology, forming a sandwich structure with a barrier film integrated into the injection moulded packaging, ensuring the scavenger is surrounded by food-contact suitable plastic and preventing premature activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polypropylene is used for packaging, then design freedom and puncture resistance are improved, but oxygen barrier properties deteriorate
Solution Approach 1:
The patent uses a composite structure combining polypropylene (for strength and design freedom) with EVOH (for oxygen barrier properties). The EVOH layer is integrated into the packaging structure through injection moulding, creating a multi-layer composite material that simultaneously provides mechanical strength and effective oxygen barrier properties, resolving the contradiction between these two requirements.
Solution Approach 2:
The packaging structure is divided into functional segments: polypropylene layers provide mechanical strength and puncture resistance, while the EVOH layer provides oxygen barrier properties. This segmentation allows each material to perform its optimal function without compromising the other, addressing both requirements simultaneously.
2Reliability
If oxygen scavenger is added to packaging material, then oxygen removal capability is improved, but premature activation during storage may occur
Solution Approach 1:
The EVOH barrier layer acts as an intermediary between the oxygen scavenger and the external environment. It controls oxygen access to the scavenger, allowing the scavenging process to start only when needed (upon opening or heating) while preventing premature activation during storage. This mediator layer resolves the contradiction between effective oxygen removal and preventing premature activation.
Solution Approach 2:
The packaging system utilizes parameter changes (temperature, pressure, or mechanical disruption) to control when the oxygen scavenger becomes active. Under normal storage conditions, the scavenger remains inactive, but when the package is opened or heated, parameters change to trigger oxygen scavenging. This temporal control resolves the contradiction between maintaining storage time and ensuring scavenging effectiveness.
3Object-affected harmful factors
If EVOH is added to polypropylene, then oxygen barrier properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the polypropylene and EVOH materials into a single integrated packaging structure through injection moulding. The EVOH layer is incorporated during the moulding process itself, combining multiple functions (strength, barrier properties, and scavenger integration) into one manufacturing step rather than requiring separate assembly operations, thus reducing overall manufacturing complexity despite the multi-material nature of the product.
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
This approach results in a high-barrier packaging article with enhanced design freedom, improved oxygen scavenging capabilities, and extended storage life of food products by maintaining the oxygen scavenger's effectiveness until needed.
Implementation Method 1
An oxygen scavenger is a substance or material capable of absorbing oxygen by a chemical reaction and thereby able to remove or reduce the content of oxygen from an enclosure.
Implementation Method 2
the walls, bottom(s) and lid(s) have barrier means for limiting permeability of oxygen through the article and into the one or more chambers
Data Source
AI summary
A packaging article for containing and holding food products includes a barrier layer for limiting permeability of oxygen through and into the article and an oxygen scavenging layer, which oxygen scavenging layer together with a second plastic material is contained within a cavity in a first plastic material forming walls, bottom(s) and lid(s) of the packaging article, which first plastic material is suitable for contact with food products. A method of manufacturing a packaging finished in one injection molding cycle includes placing the barrier layer in a mold, injecting the first plastic material suitable for contact with food products into the mold, and injecting the second plastic material with the oxygen scavenger into the mold.