Extrudable Cohesive Packaging Material for Solvent-Free Lamination
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Solution Overview
Problem
Cohesive coatings are typically manufactured using solvent coating, which is expensive and environmentally unfriendly, and they do not adhere easily to materials other than themselves, making lamination difficult and costly.
Innovation Solution
Development of an extrudable cohesive composition comprising rubber, thermoplastic elastomer, and filler, which can be co-extruded with a backing or core without the need for surface modification, allowing for the creation of a cohesive-coated material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent coating is used to manufacture cohesive coatings, then cohesive coatings can be produced, but the manufacturing process becomes expensive and environmentally unfriendly
Solution Approach 1:
The patent changes the fundamental parameter of the coating process from solvent-based application to solvent-free extrusion. The cohesive composition is formulated as an extrudable thermoplastic material that can be directly extruded onto the backing material without requiring solvents, thereby eliminating environmental harm while maintaining manufacturing feasibility
Solution Approach 2:
The patent replaces the chemical process of solvent coating with a mechanical extrusion process. The cohesive material is fed through an extruder that melts and forces the material through a die to deposit it onto the backing, substituting a mechanical manufacturing approach for the chemical solvent coating method
2Area of stationary object
If cohesive coatings are applied to materials other than themselves, then coating coverage is achieved, but adhesion is poor and lamination becomes difficult and costly
Solution Approach 1:
The patent applies local quality by designing the cohesive composition to have different properties at different stages: during extrusion it behaves as a thermoplastic that adheres to the backing material, but after cooling it transitions to a non-tacky state that does not adhere to other surfaces. This localized property change enables both good adhesion during application and non-adhesion during storage and handling
Solution Approach 2:
The patent introduces dynamic properties to the cohesive material through temperature-dependent behavior. The material transitions from a tacky, adhesive state at extrusion temperature to a non-tacky, non-adhesive state at room temperature, enabling easy lamination during manufacturing while preventing unwanted adhesion during storage and use
3Object-affected harmful factors
If cohesive coatings are made non-tacky to avoid damage to surfaces, then surface protection is improved, but adhesion to substrates deteriorates
Solution Approach 1:
The patent employs periodic action through temperature cycling during the manufacturing process. The cohesive material is heated during extrusion to become tacky and adhere to the backing, then cooled to become non-tacky and protect surfaces. This periodic temperature variation enables the material to exhibit opposite adhesive properties at different times in the process cycle
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 extrudable cohesive composition enables cost-effective and environmentally friendly manufacturing of cohesive-coated materials, with improved adhesion to themselves while avoiding damage to other surfaces, and enhances sustainability by reducing the need for solvent use.
Implementation Method 1
10 to 50 wt% thermoplastic elastomer
Implementation Method 2
thermoplastic elastomer
Implementation Method 3
10 to 45 wt% filler
Data Source
Figure 1~3
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Figure 6~7
AI summary
The present disclosure relates generally to cohesive compositions, articles including a cohesive composition, and methods of making such compositions and articles. In some embodiments, the cohesive compositions include rubber, thermoplastic elastomer, filler, and UV or heat stabilizers. In some embodiments, the cohesive articles include the cohesive composition described herein adjacent to a backing. In some embodiments, the cohesive articles further include at least one of a tie layer and a seal layer. Some embodiments of the present disclosure further relate to packaging materials that include the cohesive articles of the present disclosure. Such packaging materials may also include, for example, a cushioning layer and an outer layer. In other embodiments, the present disclosure relates to fastening systems comprising cohesive compositions and films described herein.