Plasma-Deposited Coating Layer for Container Delamination
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Solution Overview
Problem
Existing methods for producing containers, particularly bag-in-container systems, face challenges in achieving effective delamination of inner and outer layers for recyclability and efficient production, while also maintaining the freshness of contents and improving shelf-life.
Innovation Solution
A method using low-energy atmospheric plasma deposition to apply a crosslinked and covalently grafted coating layer on preforms, which enhances delamination, reduces moisture uptake, and improves heat transfer and gas barrier properties without significantly increasing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If release agents are applied onto the inner preform to optimize delamination, then delamination is improved, but the distribution becomes uneven and contamination occurs
Solution Approach 1:
The patent replaces the mechanical spray application method with plasma technology. The plasma treatment creates a uniform coating through ionized gas interaction with the preform surface, eliminating the uneven distribution and contamination issues associated with spray application while maintaining effective delamination properties
Solution Approach 2:
The patent changes the physical and chemical parameters of the preform surface treatment by using plasma. This creates a controlled environment where the coating is applied through energy field interaction rather than mechanical contact, ensuring uniform distribution and preventing contamination
2Reliability
If different materials are used for inner and outer container to achieve delamination, then delamination is improved, but recyclability deteriorates
Solution Approach 1:
The patent applies a functional coating only to the specific surface of the inner preform that contacts the outer container. This localized treatment achieves delamination functionality without requiring different materials throughout the entire structure, allowing both containers to be made from recyclable materials while maintaining the delamination function where needed
Solution Approach 2:
The patent creates a composite structure where the base material remains a single recyclable polymer, but a plasma-induced coating layer is added to the inner surface. This composite approach provides the delamination function through the coating while the base material maintains its recyclability
3Reliability
If coating layer is applied to preform, then delamination and barrier properties are improved, but material usage increases
Solution Approach 1:
The patent creates an extremely thin plasma-induced coating layer on the preform surface. This thin film approach provides the necessary delamination and barrier functions without adding significant material quantity, as the coating is formed by modifying the existing surface rather than applying a thick layer of additional material
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 plasma-deposited coating layer effectively improves delamination, reduces moisture uptake, and enhances gas barrier properties, thereby extending the shelf-life of preforms and maintaining the freshness of contents during storage and transportation.
Implementation Method 1
A method for applying a coating layer on a preform for a container using plasma deposition
Implementation Method 2
exposing coating precursors and the preform to said plasma, thereby chemically activating the precursors, the preform, or both
Implementation Method 3
depositing a coating layer on at least part of the preform by reaction of the activated precursors with each other and/or with the activated preform
Implementation Method 4
Subsequently, a container is produced by reheating the preform using infrared radiation and stretching the reheated preform into its final shape
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Container (1) with a coating layer. The invention is in the field of containers for foods and drinks. There is provided a method for applying a coating layer (2, 4) on a preform (1, 2) for a container (1) using plasma deposition. There is also provided a preform (1, 2) for a container (1), as well as a container (1) obtainable by stretching of the preform (1, 2).