Layered Paper Packaging with Wax Sealant for Gas and Steam Barriers
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Solution Overview
Problem
Existing laminates with synthetic resin films on paper substrates face challenges in recycling and do not adequately achieve both high gas and water vapor barrier properties, leading to environmental issues and insufficient performance.
Innovation Solution
A laminate comprising a paper substrate layer, a barrier layer with polyurethane resin, a flat inorganic compound, and a cationic resin, and a sealant layer with wax, which enhances both water vapor and gas barrier properties while increasing the paper ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a synthetic resin film is laminated on a paper substrate to impart gas barrier properties and water vapor barrier properties, then the barrier properties are improved, but the recyclability deteriorates and environmental problems arise
Solution Approach 1:
The patent changes the chemical composition parameters of the barrier layer by using a specific resin composition containing polyvinyl alcohol (30-70 mass%), carboxymethyl cellulose (10-40 mass%), and starch (10-40 mass%), replacing synthetic resin films with a paper-compatible coating that maintains barrier properties while enabling recyclability
Solution Approach 2:
The patent creates a composite coating material combining multiple natural polymer components (polyvinyl alcohol, carboxymethyl cellulose, starch) to achieve synergistic effects that provide both barrier properties and compatibility with paper substrate recycling
2Ease of manufacture
If a single-layer barrier layer is used to decrease the amount of plastic material, then the paper ratio is improved, but the gas barrier properties and water vapor barrier properties are insufficient
Solution Approach 1:
The patent uses a composite resin composition combining polyvinyl alcohol, carboxymethyl cellulose, and starch in specific ratios to achieve both high barrier properties and increased paper ratio in a single-layer structure
Solution Approach 2:
The patent optimizes the local composition within the barrier layer by distributing different polymer components to create regions with enhanced barrier performance while maintaining overall paper compatibility
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 achieves superior water vapor and gas barrier properties, reducing the amount of synthetic resin and improving the paper ratio, thus addressing environmental concerns and performance gaps.
Implementation Method 1
a flat inorganic compound having an average thickness of 50 nm or less and an average aspect ratio of 200 or more
Implementation Method 2
a cationic resin
Data Source
AI summary
A layered body having both high steam-barrier properties and gas-barrier properties which results in an increase in the paper percentage (biomass percentage). The layered body includes, in this order, a paper substrate layer, a barrier layer, and a sealant layer containing wax. The barrier layer contains a polyurethane resin, a flat inorganic compound having an average thickness of 50 nm or thinner and an average aspect ratio of 200 or greater, and a cationic resin.