Multi-Layer Metallized Paper-Based Packaging for Oxygen and Moisture Barriers
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Solution Overview
Problem
Existing multilayer packaging materials face challenges in achieving sufficient barrier properties under mechanical stress and are difficult to recycle due to high cohesion and adhesion of plastic layers, leading to inefficient recycling processes and environmental impact.
Innovation Solution
A multi-layer metallized paper-based packaging material with a paper layer, pre-metallization and post-metallization coating layers, including ethylene acrylic acid copolymer and butylvinyl alcohol copolymer, which provides excellent barrier properties and facilitates easy recycling by reducing polymer adhesion to cellulose fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick plastic film layer is applied to provide barrier properties, then barrier performance is improved, but recyclability deteriorates due to high cohesion and adhesion preventing separation during recycling
Solution Approach 1:
The plastic film is segmented into multiple thin layers with different functions: a barrier layer providing oxygen and moisture barrier properties, and a release layer with low adhesion to paper fibers. This segmentation allows the barrier function to be maintained while enabling easy separation during recycling, as the release layer detaches from the paper substrate in the pulping process.
Solution Approach 2:
A release layer acts as an intermediary between the barrier plastic layer and the paper substrate. This intermediate layer has low adhesion to paper fibers, facilitating easy separation during recycling while still allowing the barrier layer to provide its protective function. The release layer mediates between the need for strong barrier properties and the need for easy recyclability.
2Reliability
If extrusion or adhesive lamination is used to apply plastic layers, then barrier properties are improved, but the plastic layer becomes too cohesive and adherent to allow detachment during recycling
Solution Approach 1:
Different regions of the plastic coating have different adhesion properties: the barrier layer has strong cohesion to maintain integrity, while the release layer has deliberately low adhesion to paper fibers. This local differentiation of quality allows the structure to simultaneously provide strong barrier properties and easy separability during recycling.
Solution Approach 2:
The adhesion parameter of the plastic coating to paper is changed by introducing a release layer with specifically selected materials and thickness that provide low adhesion. This parameter change enables the plastic layer to detach easily during recycling while maintaining sufficient barrier properties through the barrier layer's inherent characteristics.
3Strength
If multilayer structures with high polymer adhesion are used, then robustness and barrier properties are improved, but recycling efficiency deteriorates with low fiber yield and high energy consumption
Solution Approach 1:
The release layer enables the extraction of the plastic barrier layer from the paper substrate during recycling. By designing the release layer with low adhesion properties, the plastic layers can be easily separated and removed from the paper fibers in the pulping process, significantly improving recycling efficiency and fiber yield while reducing energy consumption compared to strongly adherent multilayer structures.
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 packaging material maintains excellent barrier properties against oxygen and moisture transfer even under mechanical stress, with high fiber content for easy recycling, achieving high fiber yield and reduced environmental impact.
Implementation Method 1
a metallized layer comprising a metal layer
Implementation Method 2
a pre metallization coating layer
Implementation Method 3
at least one post metallization coating layer
Data Source
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AI summary
The present invention relates generally to the field of multi-layer packaging material. In particular, the present invention relates to a multi-layer metallized paper-based packaging material comprising a paper layer, a pre metallization coating layer, a metallized layer, and at least one post metallization coating layer. The present invention further relates to the use of the multi-layer metallized paper-based packaging material in accordance with the present invention to package food and to a food package manufactured from the multi-layer metallized paper-based packaging material. In one embodiment of the present invention the multi-layer metallized paper-based packaging material can be recycled with other paper packaging materials.