Elastic Film Polylactide Replacement Fossil Carbon

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Solution Overview

Problem

The existing production of elastic films for diaper fastening elements relies heavily on fossil-based materials, which are becoming scarce and environmentally detrimental, necessitating the development of alternative raw materials without compromising mechanical properties.

Innovation Solution

The use of polylactide as a second polymer component in the elastic film, replacing traditional polystyrene, combined with vegetable oil-based plasticizer oils and synthetic oils derived from synthesis gas, to reduce fossil carbon content while maintaining film elasticity, along with a coextruded structure incorporating non-elastic cover layers for easier handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polystyrene is used as the second polymer component in the elastic film, then good flowability and compatibility are achieved, but fossil raw material consumption increases and environmental impact worsens

Engineering Contradiction:

ImproveflowabilityVSAvoidfossil raw material consumption

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameter of the second polymer component from polystyrene (fossil-based) to polylactide (biodegradable polymer), thereby reducing fossil raw material consumption while maintaining the required flowability and compatibility parameters for film extrusion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite polymer system combining styrene block copolymer with polylactide, where the polylactide serves as a biodegradable processing aid that maintains the flowability and compatibility functions traditionally provided by polystyrene, thus reducing environmental impact

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If polylactide is used as the second polymer component to replace polystyrene, then fossil raw material consumption is reduced, but mechanical properties of the film may be adversely affected

Engineering Contradiction:

Improvefossil raw material consumptionVSAvoidmechanical properties

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent optimizes the proportion parameter of polylactide in the polymer mixture to achieve the right balance between reducing fossil raw material consumption and maintaining mechanical properties, finding that polylactide can effectively replace polystyrene without adversely affecting film strength

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent ensures homogeneous distribution and compatibility of polylactide with the styrene block copolymer matrix, maintaining uniform mechanical properties throughout the film while using the biodegradable polymer component

Inventive Principle:

Principle #33Homogeneity

3Object-affected harmful factors

If vegetable oil-based plasticizer is used instead of white oil, then environmental sustainability is improved, but processing characteristics may change

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidprocessing characteristics

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameter of the plasticizer from mineral-based white oil to vegetable oil-based plasticizer, improving environmental sustainability while adjusting other formulation parameters to maintain adequate processing characteristics for film extrusion

Inventive Principle:

Principle #35Parameter changes

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

This approach significantly reduces the use of fossil raw materials, improves the CO2 balance, and maintains the mechanical properties of the elastic film, allowing for partial or complete replacement of polystyrene with polylactide and the use of renewable resources, enhancing sustainability and production efficiency.

Implementation Method 1

polylactide can replace the polystyrene typically provided as an additive, so that a partial or complete replacement of polystyrene by polylactide results in an improved CO2 balance and less use of fossil raw materials

Methodology Applied

Scientific EffectViscosity reduction:

Implementation Method 2

Elastic films or at least one elastic film layer provided therein often consist of inexpensive mixtures of one or more styrene block copolymers, a plasticizer oil (white oil) and a polystyrene as a processing aid in film extrusion

Methodology Applied

Scientific EffectPhase separation:

Data Source

PatentEP2886587B1Elastic film

Publication Date: 2017.06.21 MONDI GRONAU

AI summary

The invention relates to an elastic film with at least one elastic film layer, which is formed from a polymer mixture and comprises, in addition to styrene block copolymer as a first polymer component A, at least a second polymer component B. According to the invention, the second polymer component B is polylactic acid (PLA), wherein the proportion of the second polymer component B in the elastic film is between 4 wt.% and 40 wt.%. The invention further relates to a method for producing the elastic film.