Recyclable Packaging Laminate with Foamed Barrier Layer
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Solution Overview
Problem
Current packaging laminates face challenges in achieving a balance between recyclability, low density, and high barrier properties against water, oxygen, and aroma, while also requiring flexible usage and good sealing properties.
Innovation Solution
A packaging laminate structure comprising a co-extruded and stretched first laminate layer with a substrate layer, a connecting layer, and a barrier layer, combined with a second laminate layer containing a high percentage of polyethylene, where the first laminate layer is stretched before lamination, and the second laminate layer includes a cavitated polyethylene layer for reduced weight and enhanced barrier effects, with optional metallization or coating for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a barrier layer made of aluminum or barrier polymer is added to improve barrier properties, then the barrier effect against water vapour, oxygen and aroma is improved, but the density and weight of the packaging laminate increases
Solution Approach 1:
The patent applies porous materials by incorporating a foamed polyethylene layer with controlled cell structure into the packaging laminate. This foam structure provides barrier properties against water vapour, oxygen and aroma while maintaining low density and weight, thus resolving the contradiction between barrier effectiveness and weight reduction
Solution Approach 2:
The patent uses composite materials by combining multiple layers including polyethylene, foamed polyethylene, and polyamide in a multi-layer structure. This composite approach achieves high barrier properties through the synergistic effect of different materials while keeping the overall density low, particularly through the lightweight foamed layer
2Reliability
If the barrier layer thickness is increased to improve barrier properties, then the barrier effect is improved, but the total thickness and weight of the packaging laminate increases
Solution Approach 1:
The foamed polyethylene layer provides effective barrier properties with reduced thickness compared to solid barrier materials. The closed-cell foam structure creates a tortuous path for permeation while occupying less space, thus achieving high barrier effect with minimal thickness increase
Solution Approach 2:
The patent changes the physical state of the polyethylene layer from solid to foamed structure, altering its density and thickness parameters. This parameter change allows the layer to provide barrier protection with significantly reduced thickness and weight compared to traditional solid barrier layers
3Reliability
If multi-layer structure is added to improve barrier properties, then the barrier effect is improved, but the device complexity and production cost increases
Solution Approach 1:
The patent employs a multi-layer composite structure with polyethylene, foamed polyethylene, and polyamide layers. This composite design achieves superior barrier properties by combining the advantages of each material while maintaining a relatively simple overall structure that is manageable in production
4Weight of stationary object
If cavitated polyethylene layer is added to reduce weight, then the weight and density are reduced, but the barrier properties against oxygen and aroma may be compromised
Solution Approach 1:
The patent utilizes foamed polyethylene with controlled cell structure that balances weight reduction and barrier properties. The closed-cell foam architecture provides adequate barrier against oxygen and aroma while maintaining significantly reduced weight, resolving the contradiction between lightweight design and barrier effectiveness
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
This approach significantly increases the barrier effect, reduces production costs and weight, allows for the production of lightweight and thin-walled packaging, and maintains recyclability, while providing excellent sealing properties without compromising on barrier performance.
Implementation Method 1
the first laminate layer is stretched in the machine direction (MDO) and/or in the transverse direction (TDO)
Implementation Method 2
the second laminate layer contains a cavitated polyethylene layer for reduced weight and enhanced barrier effects
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a recyclable, easily tearable packaging laminate having a good barrier effect and low density, comprising a first laminate layer (2) and a second laminate layer (3), wherein the first laminate layer (2) is a co-extruded, drawn composite consisting of a cavitated substrate layer (4) having 5-30 wt% cavitating agent and a PE proportion of at least 60 wt%, a connecting layer (5) and a barrier layer (6) consisting of a barrier polymer, preferably polyamide or ethylene vinyl alcohol copolymer, with a thickness of at most 20% of the overall thickness of the first laminate layer, wherein the connecting layer (5) is arranged between the substrate layer (4) and the barrier layer (6), and the first laminate layer (2) is connected by its barrier layer (6) to the second laminate layer (3).