Packaging Layer Arrangement with Separating Film
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Solution Overview
Problem
Current packaging solutions, such as paper-plastic composites, face challenges in recycling due to inadequate separation of plastic and paper layers, leading to contamination and inefficient disposal, which results in high thermal utilization costs and environmental impact.
Innovation Solution
A layer arrangement with a deep-drawable carrier layer, a deep-drawable cover layer, and a separating layer containing binders like nitrocellulose, carboxymethylcellulose, and starch, along with release agents like silicones and waxes, allowing for easy separation of the layers with a controlled peel force, enabling efficient recycling without residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal utilization is used for disposal of paper-plastic composite packaging, then the packaging can be disposed of, but high and accumulating fees are incurred
Solution Approach 1:
The packaging is divided into separate recyclable components: a paper carrier layer and a plastic cover layer that can be easily separated from each other. This segmentation allows each material to be processed through its respective recycling stream, eliminating the need for thermal utilization and reducing disposal costs.
Solution Approach 2:
The plastic layer is extracted from the paper packaging composite through easy separation mechanisms. This extraction enables the paper component to be recycled as pure paper material, avoiding contamination and the need for expensive thermal disposal methods.
2Strength
If plastic material permeates the paper component during lamination, then the layers are bonded together, but clear separation of layers is prevented resulting in no clear separation for recycling
Solution Approach 1:
A separating layer is introduced as an intermediary component between the paper carrier layer and plastic cover layer. This separating layer enables easy separation during recycling while maintaining proper bonding during packaging formation, resolving the contradiction between layer adhesion and recyclability.
Solution Approach 2:
The separating layer is positioned specifically at the interface between the paper and plastic layers, providing localized functionality that enables separation without compromising the overall bonding integrity of the packaging structure during use.
3Ease of manufacture
If a separating layer is introduced between carrier layer and cover layer, then separation without residue is achieved, but the structure becomes more complex
Solution Approach 1:
The separating layer is designed with specific parameters including controlled thickness (1-10 μm), specific material composition (carboxymethylcellulose, starch, or nitrocellulose binders with release agents), and controlled adhesion properties. These parameter optimizations enable easy separation while minimizing the increase in structural complexity.
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 allows for the separation of raw material phases without residue, reducing recycling complexity and energy consumption, enhancing the recyclability of paper content and producing higher-quality waste paper, while maintaining the packaging's integrity and impermeability to moisture and gases.
Implementation Method 1
the carrier layer can be separated from the cover layer in the area of the separating layer with a first peel force of 0.5 - 6 N/15 mm
Implementation Method 2
the carrier layer can be separated from the cover layer in the area of the separating layer with a first peel force of 0.5 - 6 N/15 mm
Implementation Method 3
comprising at least one release agent selected from a group consisting of second additives with a melting point of 40–250°C, in particular inorganic additives such as silicones and/or natural, synthetic and/or semi-synthetic high-viscosity waxes or wax-like substances
Implementation Method 4
the separating layer has a deep-drawable design
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to a layer assembly comprising a carrier layer having an upper side and an underside, and a cover layer having an upper side and an underside, which extends substantially over the entire upper side and/or underside of the carrier layer. The layer assembly according to the invention is characterised in that at least one separating layer is arranged between the carrier layer and the cover layer, which extends substantially over the entire surface between the carrier layer and the cover layer.