Sheetlike Composite for Food Containers with Polymer Barrier

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Solution Overview

Problem

Conventional food and drink containers, such as cans and jars, face challenges including inefficient storage due to shape, high energy consumption in production and transport, difficulty in opening, and inadequate recycling, while laminate containers with aluminum barriers have limited shelf life and environmental impact.

Innovation Solution

A sheet-like composite comprising a carrier layer, a barrier layer, and a polymer layer with specific inorganic particles and a thermoplastic polymer, designed to minimize metal content, enhance recyclability, and provide improved opening and storage characteristics, including microwave compatibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum foil is used as barrier layer, then barrier performance is improved, but environmental impact and recyclability worsen

Engineering Contradiction:

Improvebarrier performanceVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent removes aluminum from the laminate structure entirely, extracting the harmful metal component while maintaining barrier functionality through alternative organic layers. The barrier layer consists of EVOH and PVdC polymers that provide oxygen and moisture barrier properties without metal content, enabling complete recyclability of the packaging structure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention uses a composite laminate structure combining multiple polymer layers (PE, EVOH, PVdC, PP) with an adhesion promoter layer. This composite organic structure replaces the traditional aluminum-containing laminate, achieving both barrier performance and environmental compatibility through synergistic combination of different polymer materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Reliability

If aluminum foil is used as barrier layer, then barrier performance is improved, but shelf life deteriorates

Engineering Contradiction:

Improvebarrier performanceVSAvoidshelf life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent modifies the chemical composition parameters of the barrier layer by replacing inorganic aluminum with organic polymers having specific functional groups. The EVOH layer provides oxygen barrier through its hydroxyl groups, while PVdC provides moisture barrier, creating a multi-functional organic barrier system that extends shelf life through improved chemical stability and reduced metal-induced degradation.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional jars and cans are used, then production is established, but energy consumption increases

Engineering Contradiction:

Improveproduction establishmentVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by stationary object

Solution Approach 1:

The invention transitions from rigid metal cans and glass jars to flexible laminate structures made of thin polymer films. This enables production of lightweight, formable packaging that requires less energy for manufacturing and transport. The laminate can be thermally formed into various container shapes directly, eliminating the need for energy-intensive metal forming or glass blowing processes.

Inventive Principle:

Principle #30Flexible shells and thin films

4Strength

If conventional jars and cans are used, then container strength is ensured, but opening difficulty increases

Engineering Contradiction:

Improvecontainer strengthVSAvoidopening ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent introduces dynamic opening mechanisms where the laminate structure incorporates easy-open features such as perforated lines, rupture membranes, or peeling layers that allow controlled mechanical failure at designated weak points. This enables consumers to open containers with minimal force through simple pulling or pressing actions, transforming the static strong container into a dynamically openable structure that maintains strength during storage but yields easily during opening.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12115763B2Sheetlike composite, especially for production of dimensionally stable food or drink product containers, comprising a polymer layer P having an L value

Publication Date: 2024.10.15 SIG SERVICES AG

AI summary

The invention relates to a sheetlike composite comprising, as mutually superposed layers in a direction from an outer face of the sheetlike composite to an inner face of the sheetlike composite, a) a carrier layer, and b) a barrier layer; wherein the sheetlike composite additionally includes a polymer layer P comprising a first polymer; wherein the polymer layer P has an L value in the L*a*b* colour space within a range from 30 to 56. The invention further relates to methods of producing a sheetlike composite, a container precursor and a closed container and to the aforementioned method products; to a container precursor and a closed container each including at least one sheetlike region of the sheetlike composite; to uses of the sheetlike composite for production of a food or drink product container and in a microwave oven; and to uses of compositions for production of a sheetlike composite for a food or drink product container.