Multilayer Film Oxygen Scavenging Catalyst Layer
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Solution Overview
Problem
Existing packaging methods fail to reduce residual oxygen in packaging headspaces below 0.5 to 2% by volume, leading to quality deterioration of oxygen-sensitive goods, and previous solutions like oxygen adsorber materials are either non-transparent or have slow reaction rates.
Innovation Solution
A multilayer film with a catalyst layer and a barrier layer, where the catalyst is applied as a thin, patterned layer on a substrate film, and the polymer film has microperforations or is made of a nonwoven material to enhance oxygen diffusion, allowing for efficient oxygen scavenging and maintaining transparency and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complete polymer film is used to cover the catalyst layer, then the catalyst is protected, but the oxygen reduction rate is significantly reduced
Solution Approach 1:
The patent applies a microporous polymer film instead of a complete solid film to cover the catalyst layer. The microporous structure allows oxygen and hydrogen to diffuse through the film to reach the catalyst while still providing physical protection. This resolves the contradiction by maintaining catalyst protection while enabling sufficient gas permeability for effective oxygen reduction.
Solution Approach 2:
The patent applies adhesive only in specific areas (at least one adhesive area) rather than uniformly across the entire polymer film. This localized adhesive application provides necessary bonding while leaving other areas open for gas permeation, thus protecting the catalyst structure without impeding oxygen diffusion to the catalyst sites.
2Reliability
If oxygen adsorber materials are incorporated into packaging film, then oxygen reduction is achieved, but transparency is lost (e.g., when using iron oxide in plastic)
Solution Approach 1:
The patent uses a thin polymer film structure with integrated catalyst layers that is sufficiently thin to allow light transmission while containing the oxygen reduction functionality. The thin-film composite structure provides the necessary oxygen scavenging capability without the opacity associated with bulk oxygen adsorber materials like iron oxide, thus maintaining packaging transparency.
3Reliability
If a thin layer with catalyst is vapor-deposited onto substrate film, then oxygen reduction functionality is provided, but manufacturing cost increases
Solution Approach 1:
The microporous polymer film allows for optimized catalyst loading and distribution. The porous structure provides high surface area for catalyst deposition, enabling effective oxygen reduction with reduced catalyst material quantities, thus lowering material costs while maintaining functionality.
Solution Approach 2:
The patent creates a composite structure combining polymer film, adhesive layers, and catalyst components. This composite approach allows each layer to be optimized independently and manufactured using existing processes, reducing overall manufacturing complexity and cost compared to single-layer solutions requiring new fabrication methods.
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 multilayer film significantly increases the oxygen scavenging rate, reducing oxygen in packaging headspaces effectively while maintaining transparency and reducing manufacturing costs, making it suitable for oxygen-sensitive goods like pharmaceuticals and food.
Implementation Method 1
The catalyst catalyzes the reduction of oxygen, which means that disruptive oxygen is consumed in packaging materials that are sensitive to oxidation
Implementation Method 2
the oxygen contained in the headspace of a packaging being reduced by adding small amounts of a reducing gas, e.g. B. hydrogen, is catalytically converted as an oxyhydrogen reaction H 2 +1⁄2 O 2 → H 2 0
Implementation Method 3
The thin layer with the catalyst vapor-deposited onto the substrate film
Implementation Method 4
the substrate film has a barrier layer for oxygen, which prevents oxygen permeation through the multilayer film
Data Source
Figure 1~5
AI summary
A multilayer film comprising at least one substrate film (12), at least one thin film (14) containing at least one catalyst for the reduction of oxygen and deposited in a vacuum on a first side of the substrate film (12) with a thickness of 0.01 to 50 nm, and at least one polymer layer (18) arranged on the first side of the substrate film (12) above the thin film (14).To increase oxygen reduction, in the case of a polymer film (18) arranged over an adhesive layer (16), the thin film (14) is vapor-deposited onto the substrate film (12), the adhesive layer and the polymer film (18) are arranged over the thin film (14) and the adhesive layer (16) covers only a part of the surface of the thin film (14) in the form of a pattern, or the thin film (14) is vapor-deposited onto the polymer film (18) and the adhesive layer (16) is arranged between the thin film (14) and the substrate film (12), or the thin film (14) is vapor-deposited onto the substrate film (12) and the polymer layer (18) is arranged as an extrusion layer on the substrate film (12) above the thin film (14).