Multi-Layer Packaging Material With Thin Barrier Coatings
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Solution Overview
Problem
Existing multi-layer packaging materials with cellulose-based layers face issues with adherence to other layers, especially under mechanical stress, and are difficult to recycle due to polymeric materials, leading to degraded barrier properties and recyclability challenges.
Innovation Solution
A multi-layer packaging material comprising a cellulose-based layer, a tie coating layer with a polymeric binder, intermediate polymeric coating layers of polyvinyl alcohol, and a vacuum deposited metallization layer, with additional inner polymeric coating layers for improved adhesion and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric materials are deposited in thick layers by extrusion or lamination to provide robustness and barrier properties, then barrier properties to gases, moisture, and aromas are improved, but the material becomes difficult to recycle and layers break or separate under mechanical stress
Solution Approach 1:
The patent changes the thickness parameter of polymeric layers from thick (conventional) to thin (micrometer or sub-micrometer scale), achieving adequate barrier properties with minimal polymer content that enables recyclability. This parameter change resolves the contradiction between barrier performance and recyclability.
Solution Approach 2:
The patent creates a composite structure combining cellulose-based material with thin polymeric layers, where the cellulose provides the base structure and recyclability while the thin polymeric layers provide enhanced barrier properties. This composite approach balances both requirements.
2Duration of action of stationary object
If polymeric materials are deposited in thick layers by extrusion or lamination to provide robustness, then durability is improved, but the material becomes difficult to recycle
Solution Approach 1:
The patent reduces polymeric layer thickness to micrometer or sub-micrometer scale, providing sufficient durability for package functionality while maintaining recyclability through conventional paper processes. The thin layers provide adequate protection without creating recycling barriers.
3Ease of manufacture
If thin layers of polymeric materials are used to improve recyclability, then ease of recycling is improved, but adherence between layers deteriorates under mechanical stress
Solution Approach 1:
The patent introduces a tie coating layer as an intermediary between the cellulose-based material and polymeric layers. This tie layer improves adhesion and prevents layer separation under mechanical stress while maintaining the thin-layer structure for recyclability.
Solution Approach 2:
The patent optimizes polymeric layer thickness to micrometer or sub-micrometer scale, which provides sufficient mechanical integrity and layer adherence while maintaining thin-layer benefits for recyclability. The parameter optimization balances adherence and recyclability.
4Ease of manufacture
If cellulose-based material layers are used to improve recyclability, then ease of recycling is improved, but barrier properties to gases and moisture deteriorate
Solution Approach 1:
The patent creates a composite structure where cellulose-based material serves as the recyclable base and thin polymeric layers (micrometer or sub-micrometer scale) provide enhanced barrier properties. This composite approach achieves both recyclability and improved barrier performance.
Solution Approach 2:
The patent applies thin polymeric layers at micrometer or sub-micrometer thickness, which provides sufficient barrier enhancement against gases and moisture while maintaining recyclability through conventional paper processes. The parameter change enables both requirements to be met.
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 provides enhanced barrier properties against gases and moisture, maintains integrity under mechanical stress, and allows easy recycling through conventional paper processes.
Implementation Method 1
a vacuum deposited metallization layer
Data Source
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AI summary
The disclosure refers to a multi-layer packaging material comprising, from its outermost side to its innermost side, the following layers: a cellulose-based material layer having a grammage from 40 to 120 g/m2; a tie coating layer, the tie coating layer comprising a polymeric binder; an intermediate polymeric coating layer, the intermediate polymeric coating layer comprising a polyvinyl alcohol (PVA) polymer; a vacuum deposited metallization layer; and an inner polymeric coating layer, the inner polymeric coating layer comprising a material selected from a group comprising acrylic copolymers, polyesters, polyurethanes, polyester copolymers, polyurethane copolymers, vinyl acetates copolymers, chloride copolymers and any combination thereof.