PVOH Polymer Blend for Oxygen-Tight Single-Layer Packaging

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Solution Overview

Problem

Current methods for producing packaging materials with low gas permeability, particularly for food and pharmaceutical products, are costly and require elaborate production processes, such as plasma evaporation or multi-layer coatings, which are not economically viable for single-layered food containers.

Innovation Solution

A polymer blend comprising 15 to 70% polyvinyl alcohol (PVOH) and/or PVOH copolymer combined with 30 to 85% of another polymer, which can be processed through injection molding, deep-drawing, or stretching to create a packaging material with low gas permeability without the need for additional barrier layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If plasma evaporation or multi-layer coatings are used to achieve low gas permeability, then oxygen tightness is improved, but production cost and process complexity increase

Engineering Contradiction:
Improveoxygen tightnessVSAvoidproduction process complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the oxygen barrier function and the structural packaging material into a single polyvinyl alcohol-based layer, eliminating the need for separate barrier coatings or multi-layer structures. This merging of functions achieves oxygen tightness while simplifying the production process to a single-layer extrusion and forming operation.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts the oxygen barrier function from complex multi-layer structures or plasma coating processes and concentrates it into the intrinsic properties of the polyvinyl alcohol-based packaging material itself, which inherently provides low gas permeability when formulated with appropriate crystallinity and molecular weight.

Inventive Principle:
Principle #2Taking out (Extraction)

2Reliability

If plasma evaporation or multi-layer coatings are used to achieve low gas permeability, then oxygen tightness is improved, but production cost increases

Engineering Contradiction:
Improveoxygen tightnessVSAvoidproduction cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the oxygen barrier function and the structural packaging material into a single polyvinyl alcohol-based layer, eliminating the need for separate barrier coatings or multi-layer structures. This merging of functions achieves oxygen tightness while simplifying the production process to a single-layer extrusion and forming operation.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The invention uses a single-layer polyvinyl alcohol-based material that is inherently biodegradable and provides sufficient oxygen barrier properties for single-use packaging applications, eliminating the need for expensive, complex, or multi-layer structures that would be required for reusable or long-term storage applications.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Reliability

If polyvinyl alcohol content is increased to improve oxygen tightness, then gas permeability decreases, but mechanical properties and processability may deteriorate

Engineering Contradiction:
Improvegas permeabilityVSAvoidmechanical properties
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent optimizes the polyvinyl alcohol molecular weight parameters and crystallinity content to achieve the desired balance between oxygen barrier properties and mechanical strength. By carefully selecting and controlling these parameters, the material achieves low gas permeability while maintaining adequate mechanical properties for packaging applications.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The invention creates local crystalline regions within the polyvinyl alcohol matrix that provide oxygen barrier properties while the amorphous regions maintain flexibility and mechanical integrity. This local differentiation of structure allows simultaneous achievement of gas tightness and mechanical properties.

Inventive Principle:
Principle #3Local quality

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 polymer blend enables the production of cost-efficient, biodegradable packaging materials with improved oxygen tightness, extending the shelf life of packaged products and reducing waste, while maintaining mechanical properties suitable for various applications.

Implementation Method 1

Mixing polyvinyl alcohol (PVOH) and/or a PVOH copolymer and a further polymer

Methodology Applied
Scientific EffectMixing:

Implementation Method 2

The homogenous mixture obtained with step (b) as well as the extrudate obtained in step (c) or the granulate material produced in step (d) can be subjected directly and immediately to a primary shaping process, for example, injection molding

Methodology Applied
Scientific EffectHeating: Heating

Data Source

PatentUS11753536B2Oxygen-tight plastic, and packaging material produced therefrom
Publication Date: 2023.09.12 KUHL NORBERT

AI summary

The invention relates to a polymer blend comprising 15 to 70 Wt. % of polyvinyl alcohol (PVOH) and/or of a PVOH copolymer as well as 30 to 85 Wt. % of a further polymer, to a method for preparing a polymer blend, to the use of a polymer blend for producing a packaging material and to a packaging material. The packaging material obtained from the polymer blend is characterized in particular by a low gas permeability and can be produced by means of cost-effective methods.