Multi-Layer Coated Paper for Moisture Barrier Packaging
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Solution Overview
Problem
Conventional cigarette packaging materials, such as paperboard, lack effective moisture retention properties and humidity control, especially after the package is opened, and rely on non-biodegradable plastic films that increase costs and weight.
Innovation Solution
A moisture barrier coated paper material with multiple polymer layers providing heat and pressure sealability, humidity control, and humidity regulation through silica gel-impregnated or super absorbent polymer coatings, allowing for biodegradable and cost-effective packaging solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic films are used to prevent moisture loss, then moisture retention is improved, but biodegradability deteriorates and packaging costs increase
Solution Approach 1:
The patent changes the material parameters by using biodegradable polymers (PLA, PHA, PBAT, starch) instead of conventional non-biodegradable plastics, while maintaining moisture barrier properties through controlled coating thickness (0.1-10 micrometers) and specific polymer formulations that provide both biodegradability and moisture retention
Solution Approach 2:
The patent creates composite material systems by combining multiple biodegradable polymers in layered coatings, where each layer provides specific functions (barrier, flexibility, adhesion), achieving superior moisture retention while maintaining biodegradability throughout the entire packaging structure
2Reliability
If plastic films are used to prevent moisture loss, then moisture retention is improved, but packaging weight increases
Solution Approach 1:
The patent employs ultra-thin flexible polymer coatings (0.1-10 micrometers) that conform to the paper substrate, providing effective moisture barrier properties with minimal material usage and negligible weight addition, replacing thicker conventional plastic films
Solution Approach 2:
The patent optimizes the thickness parameter of the polymer coating to the minimum effective range (0.1-10 micrometers), achieving the necessary moisture barrier function with the thinnest possible layer, thereby minimizing packaging weight while maintaining protection
3Object-generated harmful factors
If ALD paper coatings are used for humidity control, then biodegradability is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing approach from complex ALD processes to conventional coating techniques (extrusion, slot-die, spray coating) that are already widely used in the industry, reducing equipment investment and operational costs while maintaining biodegradability through careful selection of polymer materials and coating parameters
Solution Approach 2:
The patent employs cost-effective biodegradable polymers that can be processed using existing manufacturing infrastructure, accepting the disposable nature of the packaging while minimizing costs through material selection and simplified processing that eliminates the need for expensive ALD equipment
4Ease of manufacture
If conventional paperboard is used, then manufacturing simplicity is maintained, but moisture retention deteriorates
Solution Approach 1:
The patent creates a composite structure combining conventional paperboard substrate with thin biodegradable polymer coatings, where the paperboard provides structural integrity and manufacturing simplicity while the polymer layer provides moisture barrier properties, achieving both goals simultaneously
Solution Approach 2:
The patent divides the packaging into functional segments: the paperboard substrate handles structural requirements and manufacturing simplicity, while the thin polymer coating layer handles moisture retention, allowing each component to optimize its specific function without compromising the other
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 multi-layer coated paper material effectively inhibits moisture exchange, maintains humidity control within the package, and reduces packaging costs and weight by eliminating the need for non-biodegradable plastic films, while allowing for simpler manufacturing processes.
Implementation Method 1
the first polymer coating, the second polymer coating, and the third polymer coating providing a barrier for moisture and air exchange through the paper material
Implementation Method 2
humidity control, and humidity regulation through silica gel-impregnated or super absorbent polymer coatings
Data Source
AI summary
A method of making a package including forming a moisture barrier coated paper material that includes a moisture barrier coated paper material including a base substrate, a first polymer coating, a second polymer coating, and a third polymer coating, the first polymer coating, the second polymer coating, and the third polymer coating applied over a first side of the base substrate, the first polymer coating, the second polymer coating, and the third polymer coating providing a barrier for moisture and air exchange through the paper material, the first polymer coating, the second polymer coating, and the third polymer coating providing heat and pressure sealability capabilities to the paper material, cutting a packaging blank from the paper material; folding the packaging blank into the package, and sealing the package by providing heat and pressure to overlapped portions of the paper material.