Cross-linked Polysiloxane Barrier for Recyclable Dairy Containers
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Solution Overview
Problem
Conventional barrier coatings for paperboard containers, such as polyolefin coatings, are not cost-efficient, non-biodegradable, and limit printability, while traditional pigment-based coatings are opaque, compromising the visibility of print images and mechanical integrity under moisture exposure.
Innovation Solution
A packaging material comprising a fiber-based substrate layer and cross-linked polysiloxane layers, which minimizes polyolefin content and provides a transparent, water-repellent barrier, enhancing recyclability and deep-temperature mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyolefin barrier coatings are used, then water and grease resistance is improved, but biodegradability and recyclability deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the barrier coating from polyolefin to cross-linked polysiloxane, maintaining barrier properties while improving biodegradability and recyclability. The cross-linked polysiloxane layer provides water and grease resistance similar to polyolefin but with enhanced environmental compatibility.
Solution Approach 2:
The patent uses a composite structure combining fiber-based substrate with cross-linked polysiloxane barrier layer. This composite material approach allows the integration of natural fiber biodegradability with the protective barrier function, eliminating the need for non-biodegradable polyolefin coatings.
2Reliability
If polyolefin barrier coatings are used, then water and grease resistance is improved, but printability deteriorates
Solution Approach 1:
The patent changes the surface chemical parameters from polyolefin to cross-linked polysiloxane, which has different surface properties that are more compatible with printing processes. The cross-linked polysiloxane provides adequate barrier properties while allowing better ink adhesion and print quality.
3Reliability
If pigment-based barrier coatings are used, then water resistance is improved, but transparency deteriorates
Solution Approach 1:
The patent changes the optical parameters of the barrier coating by using cross-linked polysiloxane instead of pigment-based coatings. The cross-linked polysiloxane forms a transparent or translucent layer that maintains water resistance while allowing light transmission, enabling visibility of printed images underneath.
4Reliability
If conventional barrier coatings are used, then barrier function is improved, but cost-efficiency deteriorates
Solution Approach 1:
The patent combines multiple functions into the cross-linked polysiloxane layer: barrier protection, printability enhancement, and environmental compatibility. This consolidation eliminates the need for separate polyolefin coating steps and reduces the number of processing units required, improving cost-efficiency while maintaining barrier function.
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 reduces polyolefin content, maintains mechanical strength, and ensures transparency and water repellency, facilitating cost-efficient, large-scale production of recyclable containers suitable for dairy and frozen foods.
Implementation Method 1
cross-linked polysiloxane layers, which minimizes polyolefin content and provides a transparent, water-repellent barrier
Implementation Method 2
The sol-gel process is a known method for producing layers of solid materials from small molecules. The process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network (or gel) of network polymers.
Implementation Method 3
The process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network (or gel) of network polymers.
Implementation Method 4
The process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network (or gel) of network polymers.
Implementation Method 5
The barrier coating should also be sealable, preferably heat-sealable.
Data Source
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AI summary
The invention relates to a converting-process of forming an open container from laminated raw materials and/or from treated laminated raw materials, particularly from a packaging material comprising at least a fiber based substrate layer [K] having an area weight, determined according to EN ISO 536, within the range of from 25 to 475 g·m-2; and one or more cross-linked polysiloxane layers [N] which have a total area weight, determined according to EN ISO 536, within the range of from 0.1 to 10 g·m-2. Preferably, the packaging material has a total content of polyolefins, preferably of any synthetic organic polymers, of at most 5.0 wt.-%, relative to the total weight of the packaging material. Preferably, the packaging material has a Cobb 600 value determined according to EN ISO 535 of below 0.2 g·m-2, preferably at most 0.1 g·m-2.