Compostable Multi-Layer Film Cap Layers Prevent Plate-Out
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Solution Overview
Problem
Existing biodegradable composite films, particularly those based on PLA and PHA resins, face issues with plate-out of low molecular weight components during processing, leading to equipment downtime and quality problems.
Innovation Solution
The development of a multi-layer composite film with cap layers composed of TUV-certified home compostable polymeric compositions, which do not contain low molecular weight components or migratory additives, to prevent plate-out and ensure proper processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If low molecular weight components and migratory additives are used to improve flexibility and processability of biodegradable films, then the film becomes more flexible and easier to process, but plate-out occurs on processing equipment causing downtime and quality problems
Solution Approach 1:
The patent extracts and removes low molecular weight components and migratory additives from the cap layer composition, allowing the film to maintain flexibility through alternative means (such as polymer selection and blending) without the harmful plate-out effect on processing equipment
Solution Approach 2:
The patent applies different compositional qualities to different layers: the core layer contains the necessary plasticizers and additives for flexibility, while the cap layer is specifically designed to be free of migratory components that cause plate-out, creating a localized solution that addresses both requirements
2Object-affected harmful factors
If PLA and PHA resins are used to create biodegradable packaging, then environmental sustainability is improved, but plate-out of low molecular weight components occurs during thermal processing
Solution Approach 1:
The patent converts the harmful plate-out effect into a beneficial outcome by using the cap layer as a protective barrier that prevents migratory components from reaching the equipment, while the core layer still provides the necessary biodegradability and flexibility functions
Solution Approach 2:
The patent creates a composite multi-layer structure combining PLA and PHA resins with carefully selected additives in the core layer, and uses a separate cap layer composition that is free of migratory components, achieving both environmental sustainability and equipment compatibility
3Reliability
If cap layers are added to prevent plate-out, then production reliability is improved, but film structure complexity increases
Solution Approach 1:
The patent segments the film into distinct functional layers (core layer and cap layer) with clear role differentiation, where the cap layer's sole function is to prevent plate-out while the core layer handles flexibility and biodegradability, making the complexity manageable and functionally efficient
Data Source
AI summary
A coextruded multi-layer compostable film comprises a core layer, a first cap layer and a second cap layer. The core layer comprises PLA resin, PHA resin and modifier X. The modifier X comprises migratory additives such as slip agents, nucleating agent, plasticizers, hydrolytic promoters, enzymes and fillers or mixtures thereof. The cap layers comprise at least 60 wt % TUV-certified home compostable composition. The content of migratory components in the cap layers is less than 0.5 wt % of the total weight of the cap layer, more preferably, less than 0.1 wt % of the total weight of the cap layer, more preferably, no migratory additives in the cap layers. The first cap layer has direct contact to the surface of the first chilled drum and the second cap layer has direct contact to the surface of the second chilled drum. In casting of a film, plate-out does not form on the surface of the chilled drums. The cap layers effectively prevent forming plate-out on the surface of processing equipment.