Filler Materials in Package Design

Cell-based cushioning material that combines the protective function of plastic with the sustainability of paper. The material has a flat structure with deformed, curved cells instead of the usual straight walls. It is made by pressing a flat cell structure to deform the cells. The curved walls provide impact protection without losing shape. The material is suitable for packaging, insulation, furniture, sports mats, etc.

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Biaxially oriented polyester film with non-slip surface, transparency, and easy winding for use in packaging applications like food containers and top seals. The film has two layers, A and B, both containing polyethylene terephthalate (PET). The dynamic friction coefficient of the A layer surface, the friction coefficient between A and B layers, and the haze are controlled within specified ranges to balance slipperiness, transparency, and processability. The film's non-slip surface prevents stacked containers from collapsing when pressed together.

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Gas barrier laminate, packaging material, and vacuum insulation material that have excellent gas barrier properties even after folding. The laminate has a specific structure with layers: a polyolefin base layer, a first polyvinyl alcohol (PVA) layer, a vapor deposition layer, and a second PVA layer. The vapor deposition layer is between the two PVA layers. The indentation hardness of the second PVA layer is 0.5 GPa or less. This laminate design provides improved gas barrier performance compared to mono-material polyolefin laminates after folding, which is important for applications like foldable packaging and vacuum insulation.

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Packaging material for roll-fed packaging machines that allows easy folding into packages without compromising sealing integrity. The packaging material has weakening elements on the fin edges. These elements are placed at transverse distances from the fin edges. When folding the material to form packages, the weakening elements guide the material bulging from the fin edges towards them. This prevents bulges forming inside the packages that can compromise sealing.

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Internal packaging material for cushioning and stabilizing objects inside shipping containers to prevent damage from external shocks. The material is designed to fix the packaging object in place while also absorbing impact forces. This provides better protection compared to just using wrapping or boxes. The cushioning material is placed inside the container around the object to absorb shocks that might be transmitted from the outside during transportation.

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A PVDC (polyvinylidene chloride) emulsion for pharmaceutical packaging that provides improved barrier properties, thermal stability, and long-term stability compared to conventional PVDC emulsions. The emulsion is made by using a silica sol as the dispersant instead of traditional surfactants. This avoids issues like decomposition, hydrolysis, migrant formation, crystallization, and poor thermal stability when heating. The silica sol also improves the water vapor barrier performance of the coating. The PVDC emulsion formulation contains 35-50% vinylidene chloride monomer, 0.5-5% comonomer, 0.1-0.5% initiator, 0.01-0.1% stabilizer, 5-7% silane coupling agent modified silica sol, and 30-5

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Biodegradable and compostable polymer compositions for flexible food packaging films that have low water vapor permeability. The compositions contain a mixture of biodegradable polyesters, including rigid polyesters like PBS, PLA, and PHA, as well as flexible polyesters like PBAT and PCL. The compositions also have small amounts of hydrophobic additives like behenamide. The blends have desirable mechanical properties like high modulus, strength, and elongation for packaging applications.

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Laminated films for packaging materials that have excellent retort resistance at high temperatures and impact resistance at high temperatures for applications like retort sterilization. The films have a layered structure with a surface layer, an intermediate layer, and a heat-sealable layer. The surface layer contains a copolymer of ethylene and a monomer like ethyl acrylate or methyl acrylate. The intermediate layer contains a copolymer of ethylene and a monomer like ethyl acrylate, methyl acrylate, or maleic anhydride. The copolymers in the layers have specific compositions and Mw/Mn ratios for balanced retort resistance and impact strength. The layered film structure provides both good retort resistance at high temperatures and impact resistance at high temperatures.

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Retortable packaging film for food products that is recyclable and provides good sealing and tear properties for retort processing. The film uses a mono-polymer laminate of biaxially oriented polypropylene (BOPP) and machine direction oriented polypropylene (MDOPP) instead of multipolymer laminates. A sealing layer with specific polypropylene terpolymer and long-chain branched polyethylene composition provides sealing strength and low melt flow index for retort compatibility. The film has at least 80% polypropylene content.

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Natural fiber-based transparent composites for food packaging that provide a sustainable alternative to fossil fuel-based packaging materials. The composites are made by UV polymerization of alkene and thiol-based monomers with natural fibers like jute. The UV radiation initiates crosslinking reactions to form a tightly bonded matrix around the fibers, resulting in high transparency (>90%) for packaging applications where visibility of contents is essential. The composites offer benefits of natural fiber composites with improved mechanical properties compared to neat polymer films.

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Paper-based packaging film with improved light barrier, moisture barrier, and recyclability for food products like butter and margarine. The film has a paper component, a polymeric film, a metallic flake layer printed on the polymeric film, and a white pigment layer between the metallic flake layer and the paper. The metallic flake layer provides light blocking, the white pigment layer enhances paper appearance, and the adhesive between the layers enables clean separation during recycling. The metallic flake grammage is kept low to balance barrier and recyclability.

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Barrier substrate for packaging containers with excellent gas barrier properties. The barrier substrate is made by coextruding a polyolefin-based stretched film with two resin layers containing polyolefin as the main component and an optional adhesive layer. A vapor deposition film is then applied to the outer surface. The barrier substrate can replace metal-coated substrates for better recyclability. The polyolefin-based barrier has good gas barrier properties and can be used in packaging containers without delamination or corrosion issues when filled with reactive contents.

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Thermoplastic resin film with improved oxygen barrier properties by adding layered minerals to olefin-based resins. The film has a matrix phase made of polyolefin resin and a dispersed phase of flat layered clay minerals. The layered clay minerals peel off to form a maze structure with long axis in film direction. The volume concentration of clay is 1-40%. This configuration provides a labyrinth effect for oxygen barrier without needing lamination or coatings.

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Oxygen and moisture barrier packaging material that uses only polyethylene film to provide sufficient barrier properties. The material consists of layers like stretched polyethylene, blocking layer, adhesive layer, non-stretched polyethylene, and can have additional components like resin barrier layer, heat-resistant layer, and printed layer. The stretched polyethylene provides initial barrier, the blocking layer prevents contaminants from reaching the adhesive, and the adhesive bonds the layers. The non-stretched polyethylene seals the contents. The material allows recycling without reducing yield since all layers are polyethylene.

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Eco-friendly vinyl packaging material that replaces aluminum and starch, decomposes over time, and reduces greenhouse gas emissions when incinerated. The packaging material contains a blend of high-density polyethylene (HDPE), low-density polyethylene (LDPE), biodegradable bionyl, and additives like stearic acid, copper, manganese, zinc, calcium carbonate, softener, and octene. The bionyl includes ethylene vinyl acetate (EVOH), a biodegradable mixed powder, and an oxidative biodegradable catalyst. The packaging is manufactured by extrusion and stretching the blended material. It can be used for food and cosmetics packaging that decomposes over time and reduces environmental impact compared to traditional vinyl.

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Multilayer substrate for packaging materials with improved gas barrier properties and adhesion between layers. The substrate has a stretched polypropylene layer sandwiched between an outer layer and an inner coating layer. The coating layer contains a resin with polar groups to improve adhesion of subsequent layers like vapor deposited films. This prevents delamination and improves gas barrier performance compared to polypropylene-only substrates. The multilayer substrate can be used in packaging applications and the packaging material is made by laminating the substrate with additional layers like vapor deposited films and sealant layers.

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Low opacity, biodegradable, and heat-sealable paper made from cellulose fibers coated with a bio-based wax to reduce opacity and improve barrier properties. The paper has a base sheet of refined softwood cellulose fibers with a basis weight of 10-25 g/m2. It is coated with a transparency agent like a coconut-based wax and a heat-sealable coating like a thermoplastic starch or protein. The coated paper has opacity less than 35% and can be used for packaging without supercalendering.

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Retail packaging solutions that address issues with securing movable product components, protecting complex curved surfaces, and maintaining product positioning during shipping. These solutions include: 1. Removable tear strip between lid and base box that clamps product inside when engaged, leaving a desirable remnant when torn. 2. Collar system for products with movable parts that provides support without constraining motion. The collars conform to the product's shape and connect with interlocking arms to form a closed loop. 3. Non-developable paper protective film for curved surfaces made by molding the paper to match the shape. The film has adhesive on both sides and a central paper layer.

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Recyclable packaging material for dense item packaging applications like pet food bags that can be processed on conventional packaging equipment. The material is a multi-layer structure with a reinforcing layer made of polyethylene textile sandwiched between other polyethylene layers like film and sealant. This allows recyclability since the layers are all polyethylene. The reinforcing layer provides strength and puncture resistance. The layers are adhered together with tie layers.

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Sealant film for packaging applications that enables recycling of mixed resin materials. The film has a layer containing recycled material with two or more resin types, followed by a separate sealant layer. The recycled layer has small, localized regions with lower transmission compared to the surrounding. These regions have maximum area and aspect ratio limits to prevent clumping. This allows recycling mixed resins while maintaining sealant and mechanical properties.

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