Paper-Plastic Composite Packaging Material for Thermoforming
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Solution Overview
Problem
Conventional plastic packaging materials are not environmentally compatible, have a negative CO2 balance, and are unsuitable for aesthetically emphasizing the exclusivity or special quality of food products, particularly those from organic and sustainable production, as they are not made from renewable or sustainably sourced materials.
Innovation Solution
A multi-layer packaging material composed of paper or cardboard layers with a thermoplastic polyolefin intermediate layer, where the plastic is extrusion-laminated between the paper or cardboard layers, enhancing bonding and reducing plastic content while maintaining barrier properties through additional plastic layers for gas and moisture impermeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pure plastic packaging material is used, then mechanical strength and deep-drawability are achieved, but environmental compatibility and aesthetic quality are compromised
Solution Approach 1:
The patent applies composite materials by combining paper/cardboard layers with plastic intermediate layers to create a multi-layer packaging material. The paper/cardboard provides mechanical strength and structural integrity, while the plastic intermediate layer provides barrier properties and enables deep-drawability. This composite structure resolves the contradiction by integrating the advantages of both materials without relying on pure plastic.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different layers of the packaging material. The paper/cardboard layers provide mechanical strength and structural form, while the plastic intermediate layer provides gas and moisture barrier properties. Each layer is optimized for its specific function, allowing the overall structure to achieve both strength and environmental compatibility.
2Reliability
If pure plastic packaging material is used, then barrier properties are achieved, but aesthetic quality and renewable material content are compromised
Solution Approach 1:
The patent uses composite materials to combine the barrier properties of plastic with the aesthetic qualities of paper/cardboard. The paper/cardboard layers can be designed with various finishes, colors, and textures that enhance aesthetic appeal and convey premium quality, while the plastic intermediate layer maintains necessary barrier properties for product protection.
Solution Approach 2:
The patent applies local quality by providing barrier properties specifically where needed through the plastic intermediate layer, while the outer paper/cardboard layers provide aesthetic functions. This localized assignment of properties allows the packaging to maintain both protection and appearance without requiring pure plastic throughout.
3Object-affected harmful factors
If plastic content is reduced, then environmental compatibility is improved, but mechanical strength and deep-drawability may be compromised
Solution Approach 1:
The patent employs composite materials to compensate for reduced plastic content by using paper/cardboard layers to provide mechanical strength. The multi-layer structure allows the packaging to achieve necessary strength and deep-drawability characteristics even with minimal plastic content, thereby improving environmental compatibility without sacrificing structural integrity.
Solution Approach 2:
The patent applies parameter changes by optimizing the basis weight and composition of paper/cardboard layers to achieve the necessary mechanical properties. By adjusting these parameters, the packaging material maintains sufficient strength and formability despite reduced plastic content, enabling environmental compatibility improvement.
4Object-affected harmful factors
If paper or cardboard layers are used instead of plastic, then renewable material content is increased, but bonding strength and layer adhesion may be compromised
Solution Approach 1:
The patent uses an intermediary approach by introducing a plastic intermediate layer that acts as a bonding agent between the paper/cardboard layers. This intermediate plastic layer provides adhesion and bonding strength, while the overall structure maintains high renewable material content through the extensive use of paper/cardboard layers.
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 significantly reduces plastic usage, maintains product shelf life and quality, and allows for conventional processing, meeting environmental and aesthetic requirements by utilizing up to 85% renewable materials while ensuring the packaging's mechanical strength and deep-drawability.
Implementation Method 1
The intermediate layer is preferably extrusion laminated between the paper or cardboard layers. In extrusion lamination, a flowable, in particular thermoplastic, material, e.g. B. via a flat die, on the surface to be laminated a layer formation, z. B. a layered composite extruded.
Implementation Method 2
Pressure is preferably applied to the layer composite after or during the extrusion lamination process so that the paper or cardboard layers bond optimally to the plastic intermediate layer. During this process, preferably liquid plastic material of the intermediate layer penetrates into the fiber structure of the paper or cardboard layers
Implementation Method 3
It is known to shape sheet-like packaging materials made of plastic in a deep-drawing process using heat to form shell-shaped packaging containers. This type of process is also referred to as thermoforming.
Data Source
Figure 1~3
AI summary
The invention relates to a multi-layered, thermoformable packaging material (1) containing at least one layer of plastic. The packaging material (1) comprises a layered composite (5) with two layers of paper or cardboard (2a, 2b) and an intermediate layer (4) of plastic, in particular polyethylene (PE).