Supported Susceptor Film Adhesive Pattern for Frozen Food Packaging
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Solution Overview
Problem
Microwave heating packages with susceptor films tend to warp or buckle during thaw cycles in freezers due to moisture absorption, and delaminate during heating due to moisture release, leading to undesirable food item displacement.
Innovation Solution
A supported susceptor film with a polymer energy interactive material between a polymer film and a support layer, where the adhesive extends across the support layer in the cross direction to stabilize it during thaw cycles and facilitate moisture venting to prevent delamination during heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If full coverage adhesive is used to join susceptor film to support layer, then warping during thaw cycles is prevented, but delamination during heating occurs due to moisture vapor pressure buildup
Solution Approach 1:
The adhesive is applied in a patterned manner rather than as full coverage, creating discrete adhesive regions separated by non-adhesive regions. This segmentation allows the structure to maintain stability where adhesive is present while providing vapor escape pathways where adhesive is absent, resolving the contradiction between preventing warping and preventing delamination.
Solution Approach 2:
Different regions of the support layer are treated differently: some regions have adhesive applied to provide dimensional stability during thaw cycles, while other regions are left non-adhesive to allow moisture vapor escape during heating. This local differentiation of adhesive presence resolves the conflicting requirements of different areas of the structure.
2Reliability
If patterned adhesive is used to allow moisture vapor escape, then delamination during heating is prevented, but warping during thaw cycles occurs due to insufficient adhesive coverage
Solution Approach 1:
The adhesive pattern is segmented into specific regions that provide sufficient coverage for dimensional stability during thaw cycles while leaving gaps for vapor escape. The segmentation strategy balances both requirements rather than prioritizing one over the other.
Solution Approach 2:
The adhesive pattern parameters (coverage area, region distribution, gap size) are optimized to achieve the dual function of providing dimensional stability during thaw cycles while enabling vapor escape during heating. By adjusting these parameters, both conflicting requirements are satisfied.
3Power
If supported susceptor film is used for microwave heating, then heating and crisping of food items is achieved, but warping and buckling occur during freezer thaw cycles
Solution Approach 1:
The adhesive is applied in specific patterns to different regions of the support layer, providing dimensional stability where needed while maintaining the overall structure's ability to handle thermal and moisture changes during freezer thaw cycles, thus preserving structural stability while maintaining microwave heating capability.
4Power
If supported susceptor film is used for microwave heating, then heating and crisping of food items is achieved, but delamination and lofting occur during heating due to moisture vapor pressure
Solution Approach 1:
The adhesive pattern is segmented to create vapor escape pathways through non-adhesive regions, allowing moisture vapor to escape during microwave heating. This prevents pressure buildup that would cause delamination and lofting, while the adhesive regions maintain sufficient bonding integrity for structural stability.
Solution Approach 2:
Different regions are differentiated: adhesive regions provide bonding integrity to prevent delamination, while non-adhesive regions provide vapor escape pathways. This local differentiation resolves the contradiction between maintaining bond integrity and allowing vapor escape during microwave heating.
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 effectively stabilizes the package against warping during thaw cycles and prevents delamination during microwave heating, ensuring consistent heating and crisping of food items without unwanted structure lofting.
Implementation Method 1
A susceptor generally comprises a thin layer of microwave energy interactive material that tends to absorb at least a portion of impinging microwave energy and convert it to thermal energy
Implementation Method 2
the adhesive extends across the support layer in the cross direction to stabilize it during thaw cycles
Implementation Method 3
during heating, the moisture in the support layer and/or adhesive is released as water vapor
Implementation Method 4
The spaces between the adhered areas are believed to serve as pathways for transporting water vapor away from the structure
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~5A
AI summary
A microwave energy interactive structure includes a susceptor film comprising microwave energy interactive material on a polymer film, a support layer joined to the microwave energy interactive material, and an adjoining layer joined to the support layer. The adjoining layer comprises a paper-based material having a machine direction and a cross direction. The adjoining layer is joined to the support layer by an adhesive region extending in the cross direction across at least a portion of the adjoining layer.