mPE Composite Food Container Sheet for Barrier and Compression Stability
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Solution Overview
Problem
Existing food and drink containers made from laminates face challenges in eco-friendliness, recycling efficiency, and longitudinal compression stability, particularly when storing fatty foods over long periods, and require improved barrier properties against oxygen and water vapor.
Innovation Solution
A sheet-like composite structure with a carrier layer, a barrier layer comprising polyolefin sublayers, and inner polymer layers with a high content of metallocene polyethylene (mPE) to enhance eco-friendliness, recycling, and longitudinal compression stability, while maintaining effective barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminium foil is used for the barrier layer, then barrier performance against oxygen, water vapor and light is improved, but energy consumption and resource intensity increase
Solution Approach 1:
The patent changes the material parameter from aluminium to polymer materials (polyethylene, polypropylene, PVDC, EVOH, PA) while adjusting thickness parameters (5-50 μm) to achieve comparable barrier performance with reduced energy consumption and improved recyclability
Solution Approach 2:
The patent employs composite laminate structures combining multiple polymer layers with different barrier properties (e.g., polyethylene + PVDC + polypropylene) to achieve aluminium-level barrier performance through material synergies rather than relying on a single metal layer
2Ease of manufacture
If conventional polymer layers are used in the laminate, then ease of manufacture is improved, but barrier performance against oxygen and water vapor deteriorates
Solution Approach 1:
The patent combines multiple polymer layers with complementary properties (e.g., polyethylene for moisture barrier, PVDC for oxygen barrier, polypropylene for structural integrity) to achieve high barrier performance while maintaining conventional manufacturing processes like extrusion and lamination
Solution Approach 2:
The patent optimizes thickness parameters (5-50 μm total barrier layer) and material composition ratios to achieve superior barrier performance without requiring complex manufacturing steps, maintaining compatibility with existing production lines
3Reliability
If thick laminate structures are used to ensure barrier properties, then barrier performance is improved, but longitudinal compression stability deteriorates when storing fatty foods
Solution Approach 1:
The patent uses composite laminate structures with polyethylene or polypropylene carrier layers providing structural rigidity and dimensional stability, combined with thinner barrier layers (5-50 μm) that prevent fatty food penetration while maintaining longitudinal compression stability during storage
Solution Approach 2:
The patent applies different material properties to different layers: the carrier layer provides mechanical strength and compression resistance, while the barrier layer provides selective permeability control, optimizing both barrier performance and structural stability locally
Data Source
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AI summary
The invention pertains to a sheet-like composite (100), comprising: a. a carrier layer (103), b. a barrier layer (105), c. an inner polymer layer F (108), and d. an inner polymer layer H (109); wherein the barrier layer (105) comprises - a barrier material layer (106), and - a barrier substrate layer (107) comprising a polyolefin; characterised in that the inner polymer layer F (108) comprises at least 40 wt.-% of a mPE, based in each case on the total weight of the inner polymer layer F (108). The invention further pertains to methods (300, 600, 700) for producing a sheet-like composite (100), a container precursor (400), and a closed container (500), to a container precursor (400), a closed container (500), and uses of the sheet-like composite (100), of a mPE, of a LDPE and of a combination of a mPE and a LDPE.