Multiwall Paper Packaging Structure for Recyclable Grease Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multiwall paper-based packaging structures that require fluorochemicals for oil and grease resistance are not recyclable and prone to grease migration through pinholes, leading to unsightly staining and non-compliance with recycling standards.
Innovation Solution
A multiwall packaging structure comprising an outer paper ply, a first intermediate paper ply, and an inner polymer film ply, secured by adhesive layers, with a high cellulosic fiber content, ensuring oil and grease resistance without fluorochemicals and preventing grease migration through pinholes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer liner is used to prevent oil/grease seepage, then oil/grease resistance is improved, but recyclability deteriorates because composite materials with polymer components exceed recycling thresholds
Solution Approach 1:
The patent removes the polymer liner from the packaging structure and replaces it with an intermediate paper ply having grease-resistant properties. This extraction of the polymer component enables the packaging to meet recyclability thresholds while maintaining oil and grease resistance through the paper-based intermediate layer.
2Reliability
If fluorochemicals are used in paper to provide oil/grease resistance, then grease migration prevention is improved, but environmental safety deteriorates due to hazardous PFAS chemicals
Solution Approach 1:
The patent eliminates hazardous fluorochemicals from the packaging structure and achieves grease migration prevention through an intermediate paper ply with inherent grease-resistant properties. This conversion removes harmful substances while maintaining the protective function against grease migration.
3Reliability
If a polymer liner is used to prevent grease seepage, then oil/grease resistance is improved, but manufacturing complexity increases due to pinhole formation and punctures from rough handling
Solution Approach 1:
The patent employs a multi-layer composite structure consisting of an outer paper ply, an intermediate grease-resistant paper ply, and an inner paper ply. This composite paper-based structure provides grease resistance without the pinhole and puncture issues associated with polymer liners, enhancing structural integrity while maintaining protective functions.
Data Source
AI summary
A paper-based packaging structure comprises an outer paper ply, a first intermediate paper ply, and an inner polymer film ply. A first adhesive layer secures the inner polymer film ply to the intermediate paper ply. A second adhesive layer secures the intermediate paper ply to the outer paper ply. The outer paper ply, the intermediate paper ply, and the inner polymer film ply are adjoined to form a multiwall structure wherein the paper-based packaging structure comprises cellulosic fiber in the range of from about 80% to about 99% by weight. In further aspects methods of forming the packaging structure and packaging articles are provided. In a further aspect, a packaging article formed of the packaging structure is provided.