Non-Foil Packaging Laminate Induction Sealing via Metal Vapour Deposition
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Solution Overview
Problem
The challenge is to develop a cost-efficient, non-aluminium foil packaging laminate for aseptic liquid food packaging that maintains gas and water vapor barrier properties and is suitable for induction heat sealing, compatible with existing packaging machines.
Innovation Solution
A non-foil packaging laminate comprising a paper or cellulose-based material coated with a metal vapour deposited layer and a durable induction sealing coating, using polymers like polyvinyl alcohol (PVOH) and ethylene vinyl alcohol (EVOH) for improved barrier properties, applied via liquid film coating, and metallised with a thin metal vapour deposition coating for heat sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminium foil is used in the packaging laminate, then gas barrier properties are excellent, but environmental profile deteriorates and cost increases
Solution Approach 1:
The invention extracts the essential function of aluminium foil (gas barrier and induction heat sealing) and implements it through alternative materials - specifically a metallised layer combined with an induction heat sealable polymer layer, eliminating the need for aluminium foil while maintaining packaging performance
Solution Approach 2:
The invention changes the material parameters by replacing aluminium foil with a composite structure of metallised layer and induction heat sealable polymer, altering the chemical composition and physical properties while achieving the same functional outcomes of gas barrier and heat sealing
2Object-affected harmful factors
If aluminium foil is removed from the laminate, then environmental profile improves, but induction heat sealing capability deteriorates
Solution Approach 1:
The invention creates a composite material structure combining a metallised layer with an induction heat sealable polymer layer, where the polymer layer contains fillers or additives that enable induction heat sealing functionality, replacing the aluminium foil's sealing capability while maintaining environmental benefits
Solution Approach 2:
The induction heat sealable polymer layer acts as an intermediary material that transfers and concentrates induction heating energy to achieve sealing, mediating between the metallised layer and the sealing requirement, thereby enabling heat sealing without aluminium foil
3Device complexity
If conventional sealing technologies are used without aluminium foil, then manufacturing complexity reduces, but sealing performance and machine compatibility deteriorate
Solution Approach 1:
The induction heat sealable polymer layer provides multi-functionality by enabling both induction heat sealing and maintaining compatibility with existing packaging machine sealing mechanisms, allowing the same packaging material to work with conventional equipment while achieving reliable seals
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 a reliable, cost-effective packaging laminate with excellent gas and water vapor barrier properties, suitable for long-term aseptic storage and induction heat sealing, maintaining package integrity and compatibility with existing machinery.
Implementation Method 1
a metal vapour deposited layer applied or vapour deposited directly onto and adjacent the inner side of said pre-coated first layer of paper or cellulose-based material, said metal vapour deposited layer being adapted to induce heat sealing in an adjacent thermoplastic polymer layer
Implementation Method 2
coating an induction sealing durable layer onto the inner side of said first layer of paper or cellulose-based material, said induction sealing durable layer comprising a polymer binder dispersed or dissolved in an aqueous or solvent-based liquid medium, and subsequent drying
Data Source
AI summary
A non-foil packaging laminate for liquid food packaging comprises a layer of paper or other cellulose-based material, outermost liquid tight, heat sealable layers of polyolefin-based polymers and, vapour-deposition coated onto the inner side of the layer of paper or cellulose-based material, an induction heat susceptible metal coating. Also disclosed is a method for manufacturing of the packaging laminate, a packaging container that is made from the packaging laminate and a method of induction heat sealing the packaging laminate into packaging containers.