Food Packaging Laminate with Reduced Antioxidants for Color Layer Adhesion
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Solution Overview
Problem
Conventional food packaging systems, such as laminate containers, face issues with reduced adhesion of color layers leading to decoration damage, tool contamination, and increased production costs due to the need for additional polymer layers, which also increase weight and transport costs.
Innovation Solution
A sheet-like composite with a specific layer sequence including a polyolefin layer, a barrier layer, and a carrier layer, where the polyolefin layer contains antioxidants and is positioned to enhance adhesion and resistance to abrasion and temperature, allowing for improved decoration durability without additional protective layers, reducing tool contamination, and maintaining lightweight properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polyolefin layer containing antioxidants is used in laminate containers, then the polyolefin layer provides protection against oxidation, but the antioxidants cause reduced adhesion of the color layer and contamination of folding/sealing tools
Solution Approach 1:
The patent divides the packaging system into separate functional layers: a polyolefin layer with antioxidants for oxidation protection, a barrier layer for moisture and oxygen barrier, and a carrier layer for structural support. This segmentation allows each layer to perform its specific function without interfering with others, resolving the adhesion problem by isolating the antioxidant-containing polyolefin from the color layer application surface.
Solution Approach 2:
The barrier layer acts as an intermediary between the polyolefin layer and the outer surface where color layers are applied. This intermediary layer prevents direct contact between antioxidants and the color layer, eliminating the adhesion issues and tool contamination while maintaining the oxidation protection function of the polyolefin layer.
2Reliability
If conventional laminate structures with multiple layers are used, then protection and barrier properties are achieved, but the structure becomes complex and production costs increase
Solution Approach 1:
The patent applies local quality by concentrating specific functions in specific layers: the polyolefin layer provides oxidation protection where needed, the barrier layer provides moisture and oxygen barrier properties, and the carrier layer provides structural strength. This localized functional assignment achieves comprehensive protection with a streamlined three-layer structure rather than multiple thick layers, reducing complexity while maintaining protection properties.
3Reliability
If glass jars or cans are used for food packaging, then long-term storage and protection are achieved, but weight increases and transportation energy consumption rises
Solution Approach 1:
The patent changes the material parameters from heavy traditional materials (glass, metal) to lightweight polymeric materials while compensating for durability through a multi-layer composite structure. The combination of polyolefin, barrier, and carrier layers provides storage durability comparable to glass or metal containers but with significantly reduced weight, lowering transportation energy consumption while maintaining long-term storage capabilities.
4Manufacturing precision
If additional polymer layers are applied to protect the color layer, then adhesion and protection are improved, but the laminate becomes heavier and production more complex
Solution Approach 1:
The patent extracts the adhesion-providing function from separate protective polymer layers and integrates it into the carrier layer itself. The carrier layer is designed with inherent adhesion properties that ensure color layer bonding, eliminating the need for additional protective layers. This approach maintains color layer adhesion while avoiding the weight and complexity increases that would result from adding more polymer layers.
Data Source
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AI summary
The invention relates to a sheet-like composite, comprising, as layer sequence: a) a first polyolefin layer, comprising i) an m-polyolefin in a proportion in a range of from 10 to 100 wt.-%, and ii) a first antioxidant in a proportion in a range of from 0 to less than 800 wt.-ppm, each range relating to the total weight of the first polyolefin layer; b) a barrier layer; and c) a carrier layer. The invention also relates to a container precursor, containing the sheet-like composite; a closed container containing the sheet-like composite in a folded state; a process for the production of a sheet-like composite; a sheet-like composite obtainable through the process; a process for the production of a container precursor; a container precursor obtainable through this process; a process for the production of a container; a container obtainable through this process; a use of the sheet-like composite; and a use of the container.