Relief Coating for Food Packaging Sheets

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Solution Overview

Problem

Conventional embossing processes are unsuitable for materials like laminated plastics used in food packaging, which lack plastic deformability, and aluminum foil packaging requires additional rigid structures for embossed effects, limiting aesthetic and protective capabilities.

Innovation Solution

A process applying a discontinuous coating with mineral fillers to create a relief pattern on packaging materials, allowing for a visual and tactile embossed effect without plastic deformation, using materials like polypropylene, polyester, or aluminum foil, and combining them to form a semi-rigid laminar structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If embossing technique is used to create surface structure, then aesthetic effect is improved, but material selection is limited to plastic-deformable materials like aluminium foil

Engineering Contradiction:

Improvesurface structureVSAvoidmaterial selection

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical embossing process (which requires plastic deformability) with a coating application process. A coating containing pigment particles is applied to the sheet material surface, and upon drying, the particles create the desired relief pattern without requiring the base material to be plastically deformable. This enables use of laminated plastics and other non-metallic materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental parameter of how surface relief is achieved - from mechanical deformation of the substrate to deposition of particulate coating material. This parameter change allows the process to work with materials that cannot be mechanically embossed, thereby expanding material versatility while maintaining aesthetic surface effects.

Inventive Principle:

Principle #35Parameter changes

2Shape

If aluminium foil is used for packaging, then aesthetic embossed effect is achieved, but protective barrier function is reduced compared to laminated plastics

Engineering Contradiction:

Improveembossed effectVSAvoidbarrier function

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent enables the use of composite laminated plastic materials (such as polypropylene/polyethylene laminates) that provide superior barrier and protective functions compared to aluminium foil. The coating process applied to these composite materials creates the embossed aesthetic effect without compromising the inherent protective properties of the laminated structure, thus achieving both aesthetic and functional requirements.

Inventive Principle:

Principle #40Composite materials

3Reliability

If laminated plastic materials are used instead of aluminium foil, then barrier function and environmental compatibility are improved, but embossed surface effect cannot be achieved

Engineering Contradiction:

Improvebarrier functionVSAvoidsurface structure

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent replaces the mechanical embossing system with a coating deposition system that applies pigment-containing coating to the laminated plastic surface. This substitution allows the creation of relief surface structures on materials like laminated plastics that lack the plastic deformability required for traditional embossing, thereby achieving both barrier functionality and aesthetic surface effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Shape

If aluminium foil is used for packaging, then aesthetic effect is achieved, but structural rigidity is insufficient requiring additional rigid cases

Engineering Contradiction:

Improveaesthetic effectVSAvoidload-bearing capacity

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The patent enables the use of laminated plastic materials that inherently provide both the desired aesthetic embossed effect (through coating application) and sufficient structural rigidity and load-bearing capacity. This eliminates the need for additional rigid protective cases that are required when using thin aluminium foil, simplifying the overall packaging structure while maintaining both aesthetic and mechanical requirements.

Inventive Principle:

Principle #40Composite materials

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

Enables the use of various packaging materials to achieve an embossed-like aesthetic effect while providing enhanced barrier protection and hermetic sealing, suitable for food products, with the ability to produce sheets for wrapping and semi-rigid housings.

Implementation Method 1

applying on the first side a coating having a relief pattern, in order to form an array of formations in relief

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS10858175B2Process for making a sheet for packaging foodstuff products

Publication Date: 2020.12.08 SOREMARTEC SA(BE)

AI summary

A process for making a sheet for packaging a foodstuff product, in particular a confectionery product, comprising the steps of:providing a sheet material (4; 101) having a first side and a second side opposite to one another; andproviding on said first side a surface structure having an array of formations in relief (2).The process is characterized in that the step of providing said array of formations in relief envisages application on said first side of a discontinuous coating (2; 106) and/or a coating having a variable thickness that forms said array of formations in relief.