Multilayer Film Odor Barrier Using Polyester Extraction
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Solution Overview
Problem
Flexible pouches used for packaging water lack adequate organoleptic barrier properties, leading to tainting from external sources such as cardboard boxes, which contain recycled fibers and additives, and the presence of an EVOH layer in coextruded films compromises abuse resistance and conformity to piercing probes.
Innovation Solution
A multilayer film with a thin PETG odor/taste barrier layer is used, comprising an outer sealant layer, bulk layer, tie layers, and an odor barrier layer, which maintains abuse and piercing properties while preventing tainting, comprising specific polymers like ethylene/α-olefin copolymers, polyamide, and cyclic olefin copolymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an EVOH layer is added to provide odor barrier properties, then water organoleptic protection is improved, but pouch abuse resistance deteriorates due to excess pinholing and breakage
Solution Approach 1:
The patent extracts the odor barrier function from EVOH and assigns it to a polyester layer instead. The EVOH layer is completely removed from the film structure, and the odor barrier properties are achieved through the polyester layer which provides both the required barrier properties and mechanical strength for pouch abuse resistance.
Solution Approach 2:
The patent changes the material parameter from EVOH to polyester for the odor barrier layer. This material substitution maintains the odor barrier function while significantly improving the mechanical properties and abuse resistance of the pouch, eliminating the pinholing and breakage issues associated with EVOH.
2Object-affected harmful factors
If an EVOH layer is added to prevent water tainting, then organoleptic barrier properties are improved, but conformity to piercing probe deteriorates resulting in leakage
Solution Approach 1:
The patent removes the EVOH layer from the film structure and replaces its odor barrier function with a polyester layer. This substitution maintains the barrier properties needed to prevent water tainting while improving the film's conformity to the piercing probe, thereby eliminating leakage issues.
3Weight of moving object
If flexible pouches are used instead of rigid bottles, then portability and weight are improved, but organoleptic barrier properties deteriorate leading to tainting
Solution Approach 1:
The patent uses a composite multilayer film structure consisting of polyester, polyolefin, and tie layers. The polyester layer provides the odor barrier properties to prevent water tainting from external sources like cardboard, while the polyolefin layers provide flexibility and light weight. This composite structure achieves both protection against tainting and the portability advantages of flexible packaging.
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 provides effective odor and taste barrier properties, ensuring the water remains untainted and maintaining high abuse resistance and conformity to piercing probes, enhancing the packaging of organoleptic-sensitive products like water.
Implementation Method 1
A first aspect is directed to a multilayer film for use in packaging organoleptic sensitive products... The odor barrier layer comprises at least one member selected from the group consisting of a polyester, amorphous polyamide, polycarbonate, polyvinylalcohol, and/or cyclic olefin copolymer
Data Source
AI summary
A multilayer film for use in packaging organoleptic sensitive products has the structure seal/bulk/tie #1/core/tie #2/tie #3/odor barrier, in which the seal layer contains a homogeneous ethylene/α-olefin copolymer having a density of at least 0.906 g/cc. The odor barrier contains a polyester, amorphous polyamide, polycarbonate, polyvinylalcohol, and/or cyclic olefin copolymer. The 7-layer film above, and variants thereof, can be produced by coextrusion, extrusion coating, lamination (via adhesive, heat, etc). Packaging articles include pouches. Packaged products have the organoleptic sensitive product in the pouch made from the film, or made from a film without the odor barrier layer, with the pouch being sealed inside a separate bag containing the odor barrier layer.