Repulpable Polymer Coated Paper Moisture Barrier
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Solution Overview
Problem
Existing tobacco packaging materials, which often include foil inner liners or polypropylene films, are not recyclable and thus not environmentally friendly, while still needing to prevent moisture loss.
Innovation Solution
A tobacco packaging material comprising a paper material coated with at least one repulpable polymer layer, optionally enhanced with a metal oxide atomic layer deposition (ALD) layer, which significantly reduces water vapor transmission rate (WVTR) to minimize the need for non-recyclable materials like foil or polypropylene films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foil inner liner or polypropylene film is used to protect tobaccos from moisture loss, then moisture barrier performance is improved, but recyclability deteriorates
Solution Approach 1:
The patent changes the material parameter from conventional polypropylene or foil to repulpable polymer coatings applied to paper. This parameter change maintains moisture barrier functionality while enabling recyclability, as the polymer coating can be removed and the paper repulped for recycling processing.
Solution Approach 2:
The invention uses composite material structure combining paper substrate with repulpable polymer coating layers. This composite approach provides the moisture barrier properties needed for tobacco protection while the paper-based composition enables recyclability through pulping processes.
2Adaptability or versatility
If repulpable polymer coating is applied to paper material, then recyclability is improved, but moisture barrier performance may deteriorate
Solution Approach 1:
The patent optimizes coating parameters including polymer type, coating weight, and application method to achieve the right balance between recyclability and moisture barrier performance. The repulpable polymer is applied in controlled amounts to provide adequate barrier properties while maintaining compatibility with recycling processes.
Solution Approach 2:
The composite structure of paper with repulpable polymer coating provides both recyclability and moisture barrier properties. The paper base maintains its recyclability through pulping while the polymer coating provides the necessary moisture protection, creating a functional composite material.
3Reliability
If polymer layer is coated onto paper material, then moisture transmission is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes coating parameters such as polymer molecular weight, coating concentration, and application speed to reduce manufacturing complexity. By selecting appropriate polymer characteristics and coating conditions, the process achieves effective moisture barriers without requiring overly complex equipment or multi-step procedures.
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 a fully recyclable tobacco packaging material with excellent moisture barrier properties, allowing for the elimination of foil inner liners and polypropylene films without compromising the protection against moisture loss, thus enhancing environmental sustainability.
Implementation Method 1
a paper material coated with at least one polymer layer, wherein the polymer layer comprise at least one repulpable polymer, and wherein the tobacco packaging material has a water vapor transmission rate (WVTR) that is at least 90% lower than the paper material
Implementation Method 2
at least one ALD layer, wherein the ALD layer comprises a metal oxide
Data Source
AI summary
Provided herein is a tobacco packaging material, comprising a paper material coated with at least one polymer layer. The polymer layer comprises at least one repulpable polymer, and wherein the tobacco packaging material has a water vapor transmission rate (WVTR) that is at least 90% lower than the paper material. Further provided is a tobacco package comprising the tobacco packaging material, wherein the tobacco package is substantially free of any foil inner liner or polypropylene film. Further described is a method for making the tobacco packaging material, comprising extrusion coating at least one repulpable polymer onto a paper material to form a polymer layer, and optionally further depositing at least one atomic layer deposition (ALD) layer that comprises a metal oxide.