Delamination Container Outer Layer Composite for Dimensional Stability
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Solution Overview
Problem
Delamination containers with polypropylene resin outer layers and ethylene-vinyl alcohol copolymer resin inner layers experience dimensional variations during blow molding, leading to air leakage and compromised dispensing efficiency due to the high melt flow rate of polypropylene and reduced peelability with polyethylene resin outer layers.
Innovation Solution
A delamination container design featuring a polypropylene resin inner sub-layer, a polyethylene resin outer sub-layer, and an ethylene-vinyl alcohol copolymer resin inner layer, with a modified polyolefin resin innermost layer and a strip-shaped adhesive layer, along with an ambient air introduction hole, to maintain gas barrier properties and stability while ensuring smooth peeling and dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the outer layer body is made of polypropylene resin to achieve ease of manufacture, then the container can be easily produced by blow molding, but dimensional variation increases leading to air leakage
Solution Approach 1:
The outer layer body is constructed as a composite of polypropylene resin (providing ease of manufacture and cost-effectiveness) and polyethylene resin (providing dimensional stability). This composite structure allows the container to benefit from both materials: the polypropylene enables easy blow molding production while the polyethylene component reduces dimensional variation and prevents air leakage between the container and dispensing plug.
2Manufacturing precision
If the outer layer body is made of polyethylene resin to improve dimensional stability, then manufacturing precision improves, but peelability of the inner layer body deteriorates
Solution Approach 1:
The outer layer body uses a composite structure where polyethylene resin provides dimensional stability while polypropylene resin maintains good peelability with the ethylene-vinyl alcohol copolymer inner layer. The composite allows simultaneous achievement of both dimensional stability (from polyethylene) and ease of peeling (from polypropylene's compatibility with EVOH).
Solution Approach 2:
Different regions of the outer layer body have different resin compositions optimized for different functions: the polyethylene component addresses dimensional stability requirements, while the polypropylene component addresses peelability requirements. This local differentiation of material properties resolves the contradiction between dimensional stability and peelability.
3Productivity
If polypropylene resin with high melt flow rate is used to achieve ease of manufacture, then manufacturing efficiency improves, but dimensional variation increases
Solution Approach 1:
The outer layer body composite combines polypropylene resin (enabling high melt flow rate and efficient manufacturing) with polyethylene resin (providing dimensional stability). This allows the production process to benefit from the high processability of polypropylene while the final product achieves dimensional stability from the polyethylene component, resolving the contradiction between manufacturing efficiency and dimensional precision.
Data Source
AI summary
A method for producing a delamination container, wherein the delamination container includes an outer layer body constituting an outer shell of the container and an inner layer body that is laminated on an inner side of the outer layer body in a manner such that the inner layer body is peelable from the outer layer body. The inner layer body comprises an ethylene-vinyl alcohol copolymer resin, and is deformable to undergo volume reduction and the outer layer body includes an outer layer body's inside sub-layer that is located adjacent to the inner layer body and that is made of a polypropylene resin and an outer layer body's outside sub-layer that is located on an outer side of the container relative to the outer layer body's inside sub-layer and that is made of a polyethylene resin. The method comprises a process to form the delamination container by co-extruding resins in a molted state to prepare a cylindrical laminated parison and blow molding the prepared laminated parison.