Polyvinyl Alcohol Barrier Layer for Recyclable Packaging

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current packaging solutions with aluminum-based barrier layers pose health risks and are difficult to recycle due to thermal processing issues, and polyvinyl alcohol (PVOH) layers suffer from poor water resistance and adhesion on hydrophobic surfaces.

Innovation Solution

A packaging element with a barrier layer composed of at least 90% uncrosslinked polyvinyl alcohol or its copolymers, such as poly(vinyl alcohol-co-vinylamine), poly(vinyl alcohol-co-ethylene glycol), and poly(vinyl alcohol-co-acrylamide, without metal layers, achieving low water vapor permeability through optimized layer thickness and interface properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum layer is used as barrier layer, then water vapor barrier property is improved, but health safety and recyclability deteriorate

Engineering Contradiction:

Improvewater vapor barrier propertyVSAvoidhealth safety

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from aluminum to uncrosslinked polyvinyl alcohol, transforming the barrier layer composition to eliminate metal health concerns while maintaining barrier functionality through the polymer's molecular structure and hydrogen bonding capabilities

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a disposable, easily recyclable polymer material that can be thermally processed and separated without the complications of metal contamination, enabling straightforward recycling streams and eliminating aluminum's recyclability barriers

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If aluminum layer is used as barrier layer, then water vapor barrier property is improved, but recyclability deteriorates

Engineering Contradiction:

Improvewater vapor barrier propertyVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from aluminum to uncrosslinked polyvinyl alcohol, enabling thermal recyclability through the polymer's melting and reprocessing capabilities while maintaining barrier performance through controlled layer thickness and molecular architecture

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If polyvinyl alcohol is used as barrier layer, then health safety and recyclability are improved, but water resistance deteriorates

Engineering Contradiction:

Improvehealth safetyVSAvoidwater resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent optimizes the degree of hydrolysis parameter of polyvinyl alcohol to achieve a balance between water solubility and water vapor barrier properties, utilizing the polymer's hydrophilic-hydrophobic characteristics to create effective water vapor resistance while maintaining health safety

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure combining polyvinyl alcohol with complementary materials or surface treatments that enhance water resistance while preserving the inherent health safety benefits of the polymer, achieving synergistic performance across multiple properties

Inventive Principle:

Principle #40Composite materials

4Object-affected harmful factors

If polyvinyl alcohol is used as barrier layer, then health safety and recyclability are improved, but adhesion on hydrophobic surfaces deteriorates

Engineering Contradiction:

Improvehealth safetyVSAvoidadhesion

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent introduces a primer layer or surface treatment as an intermediary between the hydrophobic substrate and the hydrophilic polyvinyl alcohol barrier layer, facilitating adhesion through compatible surface chemistry and mechanical interlocking while preserving the health safety benefits of the polymer system

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides improved recyclability, environmental compatibility, and biocompatibility, achieving water vapor barrier properties comparable to aluminum-based composites while allowing for optical transparency and simplified quality control.

Implementation Method 1

the barrier layer has a water vapor permeability of a maximum of 0.8 g/(m 2 d)

Methodology Applied

Scientific EffectPermeation: Permeation

Data Source

PatentEP3098070B1Packaging element

Publication Date: 2020.07.15 LENZING PLASTICS

AI summary

The invention relates to a packaging element made of a composite material comprising a polymeric carrier layer and a barrier layer bonded to the polymeric carrier layer, the barrier layer having a water vapor permeability of at most 0.8 g/(m2d), in particular at most 0.05 g/(m2d), at 23 °C and 85% relative humidity according to standard ISO 15106-2:2003, wherein the barrier layer comprises a polymer of at least 90 wt%, and wherein the polymer is selected from the group comprising uncrosslinked polyvinyl alcohol, water-soluble polyvinyl alcohol copolymers, such as poly(vinyl alcohol-co-vinylamine), poly(vinyl alcohol-co-ethylene glycol), poly(vinyl alcohol-co-acrylamide), and poly(vinyl alcohol-co-acrylic acid).