Sheetlike Composite for Dimensionally Stable Food Containers
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Solution Overview
Problem
Conventional food and drink packaging in cans and jars has disadvantages such as limited space efficiency, high weight leading to increased transport energy, high energy expenditure in production, and challenges in labeling and preserving printed images during autoclaving.
Innovation Solution
A sheetlike composite comprising a first polymer layer with a specific ratio of aromatic to carbonyl groups, a carrier layer of cardboard or paper, and an oxygen barrier layer, which can be produced with energy savings and high processing speed, allowing for intaglio printing and enhanced mechanical stability of color decorations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cans and jars are used for packaging, then preservation and sealing are achieved, but weight increases leading to higher transport energy expenditure
Solution Approach 1:
The patent employs a multi-layer composite structure consisting of a polymer layer (with specific aromatic to carbonyl group ratio of 0.18-0.34), a carrier layer (cardboard, paperboard, or paper), and an oxygen barrier layer (polyamide, polyethylene vinyl alcohol, metal, or metal oxide). This composite material achieves the preservation and sealing functions of traditional cans and jars while using lighter-weight materials, thereby reducing transport energy expenditure.
2Reliability
If glass, tinplate or aluminium are used for container production, then durability and sealing are improved, but energy expenditure in production increases
Solution Approach 1:
The patent replaces energy-intensive materials like glass, tinplate, and aluminium with a composite structure made from polymer, cardboard/paper, and oxygen barrier layers. This composite material provides comparable durability and sealing properties while significantly reducing the energy required for production, as these materials can be processed at lower temperatures and with less energy consumption.
3Loss of information
If printed images are applied to containers, then identification and promotion are enabled, but images may be damaged during autoclaving
Solution Approach 1:
The patent applies the printed image directly to the polymer layer during the container formation process, before the autoclaving step. The specific chemical composition of the polymer layer (with aromatic to carbonyl group ratio of 0.18-0.34) provides a stable substrate that protects the printed image from damage during subsequent autoclaving, thereby preserving image integrity while maintaining autoclave resistance.
4Ease of manufacture
If jars are transported from glass factory to dispensing facility, then production is separated, but transport volume and energy increase
Solution Approach 1:
The patent separates the container body production from the final assembly and filling process. The sheetlike composite is manufactured separately and then formed into containers at the dispensing facility, just in time for filling. This segmentation allows local production of containers, reducing transport volume and energy requirements while maintaining the benefits of specialized manufacturing.
5Ease of operation
If cans are opened, then access to contents is achieved, but sharp edges cause injury risk
Solution Approach 1:
The patent employs a flexible composite structure with a polymer layer and carrier layer that allows the container to be opened without creating sharp edges. The material properties of the composite enable controlled opening mechanisms that maintain safety, eliminating the sharp edge problem associated with traditional metal cans while preserving easy access to contents.
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 composite provides a dimensionally stable laminate container with extended shelf life, undamaged printed images, and reduced energy consumption in production and transport, while allowing for efficient and labor-saving packaging and labeling processes.
Implementation Method 1
the first polymer layer is characterized by a ratio of a proportion of aromatic groups in the first polymer layer to a proportion of carbonyl groups in the first polymer layer in a range from 0.18 to 0.34
Implementation Method 2
an oxygen barrier layer which is selected from a. a plastic barrier layer which comprises at least 70 % by weight of polyamide or polyethylene vinyl alcohol or a mixture thereof, b. a metal layer, c. a metal oxide layer
Data Source
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AI summary
The invention relates to a sheetlike composite comprising, as layers of a layer sequence in the direction from an outer face of the sheetlike composite to an inner face of the sheetlike composite, a) a first polymer layer, b) a carrier layer, and c) a barrier layer, wherein the first polymer layer is characterized by a ratio of a proportion of aromatic groups in the first polymer layer to a proportion of carbonyl groups in the first polymer layer in a range from 0.18 to 0.34. The invention further relates to processes for producing a sheetlike composite, a container precursor and a closed container and to the aforementioned process products; to a further container precursor; to a further closed container; and to uses of the sheetlike composite, of a hardener and of a printing ink.