Sheetlike Composite for Containers with Variable Thermoplastic Layer Thickness
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Solution Overview
Problem
Conventional food and drink containers, such as cans and jars, face issues with storage efficiency, weight, energy consumption in production and transport, ease of opening, risk of injury, and limitations in decoration and printing capabilities, as well as difficulties in maintaining a secure grip, especially under moist conditions.
Innovation Solution
A sheet-like composite container comprising multiple layers, including a thermoplastic layer A, a carrier layer, a barrier layer, and an inner polymer layer, with specific layer thickness and composition configurations to enhance printing capabilities, grip, and environmental sustainability, and utilizing polyvinyl acetal for sealing and joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional single-layer thermoplastic structure is used for containers, then manufacturing is simple, but printing capability and surface quality are insufficient
Solution Approach 1:
The patent employs a multi-layer composite structure consisting of a thermoplastic layer, a carrier layer (paper or cardboard), and a seal layer. This composite construction allows each layer to contribute its specific properties: the thermoplastic layer provides printing capability and surface quality, the carrier layer provides structural strength and rigidity, and the seal layer provides sealing functionality. This resolves the contradiction by combining materials with different properties to achieve both manufacturing simplicity and enhanced printing capability.
2Reliability
If a thick thermoplastic layer is applied over the entire surface for sealing, then sealing capability is improved, but material consumption and cost increase
Solution Approach 1:
The patent applies the seal layer selectively only in regions where sealing is required (such as the bottom seam area), rather than covering the entire container surface. This localized application maintains adequate sealing capability at critical points while significantly reducing the total amount of thermoplastic material consumed, thereby resolving the contradiction between sealing reliability and material consumption.
3Strength
If a uniform multi-layer structure is used throughout the container, then structural integrity is maintained, but sealing efficiency and material distribution are suboptimal
Solution Approach 1:
The patent divides the container structure into distinct zones with different layer configurations: a first region with a complete multi-layer structure (thermoplastic layer A, carrier layer, barrier layer, inner polymer layer) for structural integrity, and a second region with a simplified structure (thermoplastic layer B, carrier layer, barrier layer, inner polymer layer) where thermoplastic layer A is omitted. This segmentation allows the container to maintain structural strength where needed while improving sealing efficiency and reducing material usage in specific areas.
4Adaptability or versatility
If conventional printing methods are used on polymer surfaces, then printing is possible, but the number of suitable ink systems is limited and preparation is complex
Solution Approach 1:
The patent introduces a carrier layer made of paper or cardboard between the thermoplastic layer and the outer environment. This carrier layer serves as an alternative substrate for printing, offering superior compatibility with various ink systems compared to pure polymer surfaces. The carrier layer's porous and absorbent nature allows for simpler printing preparation and broader ink compatibility, thereby resolving the contradiction between printing versatility and preparation complexity.
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 an improved, sustainable container that is easier to print on, grip, and seal, with enhanced decoration options and reduced environmental impact, while ensuring high seal strength and safety.
Implementation Method 1
a layer thickness of the thermoplastic layer A in the first composite region is more than a layer thickness of the first thermoplastic layer B in the second composite region
Implementation Method 2
c) a barrier layer
Implementation Method 3
use of a polyvinyl acetal for joining a fold-over excess to a body of a closed container
Data Source
AI summary
The invention relates to a sheetlike composite (100) comprising a first composite region (101) and a second composite region (102); wherein the first composite region (101) comprises, as mutually superposed layers from an outer surface (104) of the first composite region (101) to an inner surface (103) of the first composite region (101): a) a thermoplastic layer A (110), b) a carrier layer (108), c) a barrier layer (106), and d) an inner polymer layer (105); wherein the outer surface (104) of the first composite region (101) is a surface of the thermoplastic layer A (110); wherein the second composite region (102) comprises, as mutually superposed layers from an outer surface (104) of the second composite region (102) to an inner surface (103) of the second composite region (102): A) a first thermoplastic layer B (109), B) the carrier layer (108); C) the barrier layer (106); and D) the inner polymer layer (105); wherein the outer surface (104) of the second composite region (102) is a surface of the first thermoplastic layer B (109); wherein the second composite region (102) does not comprise any part of the thermoplastic layer A (110); wherein a layer thickness (111) of the thermoplastic layer A (110) in the first composite region (101) is more than a layer thickness (112) of the first thermoplastic layer B (109) in the second composite region (102). The invention further relates to a process of printing a sheetlike composite; to a container precursor; to closed containers; to a device for printing; and to use of a polyvinyl acetal.