Outer Polymer Layer Density Control for Ultrasound Sealing
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Solution Overview
Problem
Existing laminate packaging systems face issues with processing difficulties during ultrasound sealing, leading to contamination, tool maintenance challenges, and reduced productivity due to the detachment of the outer polymer layer, which affects the quality and leak tightness of foodstuff containers.
Innovation Solution
A sheetlike composite with a specific layer sequence, including an outer polymer layer of defined density (920-925 kg/m³) and melting temperature (107.5-115 °C), comprising at least 50 wt.% polyolefin, is designed to improve ultrasound sealing efficiency and reduce contamination, allowing for higher production rates and longer tool maintenance intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an outer polymer layer is used in laminate packaging, then the container provides protection and structural integrity, but the outer polymer layer detaches during ultrasound sealing causing contamination and requiring tool maintenance
Solution Approach 1:
The patent applies parameter changes by precisely controlling the density of the outer polymer layer to fall within the range of 915-930 kg/m³, and the melting temperature to be 105-120°C. These parameter optimizations ensure the polymer layer maintains appropriate adhesion during ultrasound sealing while providing necessary protection, preventing detachment and contamination issues
Solution Approach 2:
The patent employs composite materials by creating a multi-layer laminate structure consisting of an outer polymer layer, color application layer, carrier layer, and barrier layer. This composite structure combines materials with complementary properties: the outer polymer layer provides protection and controlled sealing behavior, the carrier layer provides structural support, and the barrier layer provides moisture and oxygen resistance, collectively preventing layer detachment while maintaining container integrity
2Reliability
If conventional laminate structures are used, then the container provides basic protection, but processing difficulties during ultrasound sealing reduce productivity and increase maintenance requirements
Solution Approach 1:
The patent optimizes processing parameters by controlling the outer polymer layer density (915-930 kg/m³) and melting temperature (105-120°C), which enables efficient ultrasound sealing at lower energies. This parameter optimization reduces processing difficulties, increases production rates, and extends tool maintenance intervals by preventing polymer accumulation on sealing tools
Solution Approach 2:
The patent replaces conventional mechanical sealing methods with ultrasound sealing technology. The ultrasound energy selectively melts and bonds the outer polymer layer without requiring high mechanical pressures, reducing processing difficulties and tool wear while maintaining container protection and increasing productivity
3Reliability
If additional sealants are used to improve leak tightness, then the container achieves better sealing, but the process becomes more complex and requires additional materials
Solution Approach 1:
The patent applies the self-service principle by designing the outer polymer layer with specific properties (density: 915-930 kg/m³, melting temperature: 105-120°C) that enable it to self-seal during ultrasound sealing without requiring additional sealants. The polymer layer itself provides the sealing function through controlled melting and bonding, simplifying the sealing process while maintaining leak tightness
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 optimized laminate composite ensures high production rates, maintains tool efficiency, and achieves longer shelf life with improved leak tightness and reduced oxygen and water vapor transmission rates, facilitating easier decoration and storage without additional sealants.
Implementation Method 1
the outer polymer layer is further characterised by a melting temperature according to the test method described herein in the range from 107.5 to 115 °C
Data Source
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AI summary
The present invention refers to a sheetlike composite (100), comprising as a layer sequence in a direction from an outer surface (101) of the sheetlike composite (100) to an inner surface (102) of the sheetlike composite (100) a) an outer polymer layer (103), b) a colour application (104), c) a carrier layer (105), and d) a barrier layer (107); wherein the outer polymer layer (103) is characterised by a density in a range from 919 to 925 kg/m3. The invention further refers to a container precursor (500) and to a container (700), in each case comprising at least part of the preceding sheetlike composite (100); to processes (300, 400, 600) for preparing a sheetlike composite (100), a container precursor (500), and a closed container (700); to the preceding products; and to uses of the sheetlike composite (100), and of a polyolefin.