Tube Structure with Spot Barrier Layer
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Solution Overview
Problem
Conventional tube packaging materials absorb antibacterial compounds, flavors, and fragrances, leading to degradation and loss of product properties, and the use of barrier layers complicates manufacturing and increases costs.
Innovation Solution
A tube structure with a spot barrier layer applied to the inner surface, excluding the seal areas, formed by a laminate structure that includes a polyethylene film, coextruded tie layers, and a polymer layer, ensuring minimal absorption of product components while maintaining seal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a full barrier layer is applied to the tube structure, then absorption of antibacterial compounds and flavors is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies barrier properties selectively only to the tube body portion that contacts the product, while excluding the seal area from barrier layer coverage. This local differentiation reduces manufacturing complexity by eliminating the need to handle barrier materials in seal areas, while still providing absorption protection where needed.
Solution Approach 2:
The tube structure is segmented into distinct functional zones: a barrier-lined tube body for product contact and absorption prevention, and a barrier-free seal area for sealing operations. This segmentation allows each zone to be optimized for its specific function without the complications of applying barrier materials throughout the entire tube.
2Loss of substance
If a barrier layer is applied to the tube, then product component absorption is reduced, but sealing becomes more difficult
Solution Approach 1:
The barrier layer is applied selectively to the tube body while deliberately excluding the seal area. This creates a local quality difference where the tube body has barrier properties to prevent absorption, while the seal area remains free of barrier materials to ensure proper sealing performance and ease of manufacture.
3Loss of substance
If barrier materials are used to prevent absorption, then flavor and fragrance loss is reduced, but additional manufacturing steps are required
Solution Approach 1:
The barrier layer is applied only to the tube body portion where product contact occurs, while the seal area is intentionally left without barrier material. This selective application eliminates additional manufacturing steps that would be required to apply and then remove or modify barrier materials in seal areas, thereby improving manufacturing efficiency while still preventing flavor and fragrance loss in the product contact zone.
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 reduces the absorption of flavors, fragrances, and antibacterial compounds, preserving product properties and simplifying the manufacturing process by avoiding additional manufacturing steps required for full barrier layers.
Implementation Method 1
the antibacterial compound may be absorbed or otherwise degraded by the tube materials
Data Source
AI summary
A method of making a tube (60) includes forming at least one tube layer (101, 106, 108); and forming at least one film layer (102, 103, 104) on the at least one tube layer, wherein the at least a portion of the at least one film layer does not completely overlap the at least one tube layer.