Molded Fiber Container With Gas-Tight Film Liner
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Solution Overview
Problem
Existing packaging solutions for sterilized liquid or pasty foods are not suitable for aseptic filling due to permeability issues, and current aseptic packaging materials are complex, costly, and difficult to recycle.
Innovation Solution
A container with a tubular base body and molded fiber parts coated with a multi-layer film that acts as a gas-tight and liquid-tight barrier, using materials like pulp for the molded fiber parts and a laminate for the base body, which can include cardboard, paper, plastic, or aluminum layers, to prevent microbial growth and oxygen entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex laminates with plastic and aluminum layers are used for aseptic packaging, then the container can prevent microorganism entry and ensure long shelf life, but the material costs increase and the layers become difficult to separate for recycling
Solution Approach 1:
The patent divides the packaging system into separate functional components: a molded fiber container body and a separate flexible film liner. The liner is inserted into the container rather than being laminated to it, allowing the two materials to be easily separated after use for recycling. This segmentation maintains aseptic functionality while simplifying the overall structure and improving recyclability.
Solution Approach 2:
The flexible film liner acts as an intermediary element between the fiber container and the liquid food product. It provides the gas-tight and liquid-tight barrier properties needed for aseptic packaging, while the fiber container provides structural support. This intermediary approach allows each material to perform its optimal function without requiring complex lamination.
2Ease of manufacture
If molded fiber parts are used for packaging, then the containers can be reused very well as recyclable material, but they are unsuitable as aseptic packaging due to their permeability
Solution Approach 1:
The patent creates a composite packaging system combining molded fiber material with a flexible film liner. The fiber material provides excellent recyclability and structural properties, while the film liner provides the necessary gas-tight and liquid-tight barrier properties. Together they form a composite solution that achieves both recyclability and aseptic packaging requirements.
3Device complexity
If conventional packaging materials are used, then the container structure is simple, but the container is not suitable for aseptic filling of liquid or pasty foodstuffs
Solution Approach 1:
The flexible film liner is pre-formed and inserted into the fiber container before filling. This preliminary action ensures that the aseptic barrier is already in place and properly positioned, enabling the container to be filled with liquid or pasty foodstuffs under aseptic conditions without requiring complex integrated 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 solution enables aseptic filling and storage of liquid or pasty foods by creating a sterile environment within the container, while reducing plastic and metal usage and allowing for recyclability, thus addressing the limitations of existing packaging materials.
Implementation Method 1
the inside of the at least one molded fiber part is coated gas-tight and liquid-tight by means of a multi-layer film, which can also contain a barrier layer
Implementation Method 2
the base body encloses the molded fiber part, is guided around the edge of the molded fiber part
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
The invention relates to a container for receiving contents, in particular liquid foods, having a tubular main body and having at least one molded fiber part (2) connected to the main body (1), and to a method for producing such a container. For the container to be suitable for being aseptically filled with liquid or paste-like foods, according to the invention, the inner face of the at least one molded fiber part (2) is coated to be gas and liquid tight. According the invention, the container is produced as follows: pressing at least one molded fiber part (2) from pulp, coating the inner face(s) of the molded fiber part or parts, providing the tubular main body, connecting the main body (1) to the (first) molded fiber part for generating a container that is open on one side, filling the container through the open side, and closing the container by folding or by joining to the (further) molded fiber part.