Flowable Polymer Layer Application for Tube Laminate Air Inclusion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for producing multi-layer packaging laminates, particularly for tube containers, face constraints and potential production faults due to the use of prefabricated polyolefin films as outermost surfaces, which can lead to air inclusion and complexity in layer application.

Innovation Solution

A method where the second polymer layer arrangement is applied in a flowable state onto the first polymer layer arrangement, allowing for easier modification and reduction of air inclusion, with all layers except the polyolefin film base layer applied in a flowable state, using extruder stations and coating techniques to form a multi-layer laminate with a water vapor and/or oxygen transmission barrier layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If prefabricated polyolefin films are used as outermost surfaces in coextrusion-lamination, then the laminate structure is formed, but air inclusion occurs and production complexity increases

Engineering Contradiction:

Improvelayer application processVSAvoidair inclusion risk

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the physical state parameter of the polymer material from solid prefabricated film to flowable state during application. The second polymer layer arrangement is applied in a flowable state onto the first polymer layer arrangement, allowing the material to flow and conform to the underlying layers, thereby eliminating air pockets and ensuring complete contact between layers while simplifying the application process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The base layer with the first polymer layer arrangement is prepared and positioned in advance at the first application station before the second polymer layer arrangement is applied. This preliminary preparation ensures that the receiving surface is ready and properly positioned, allowing the flowable second layer to be applied smoothly without air inclusion

Inventive Principle:

Principle #10Preliminary action

2Productivity

If prefabricated polyolefin films are used as outermost surfaces, then the laminate can be produced, but the process complexity and potential for production faults increase

Engineering Contradiction:

Improveproduction efficiencyVSAvoidcoextrusion-lamination process

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent simplifies the production process by changing the application method of the second polymer layer arrangement from coextrusion-lamination of prefabricated films to application in a flowable state. This parameter change reduces the complexity of the production process and minimizes potential faults while maintaining productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts the second polymer layer arrangement from the prefabricated film form and applies it directly in a flowable state. This eliminates the need for complex coextrusion-lamination equipment and processes associated with handling and bonding two separate prefabricated films, thereby reducing device complexity and potential production faults

Inventive Principle:

Principle #2Taking out (Extraction)

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 reduces the risk of air inclusion and simplifies the layer application process, resulting in a more reliable and efficient production of multi-layer packaging laminates with improved recyclability and sealability, suitable for forming collapsible tube packaging containers.

Implementation Method 1

applying a first polymer layer arrangement in a flowable state onto the base layer at a first application station

Methodology Applied

Scientific EffectFlow:

Implementation Method 2

applying a second polymer layer arrangement onto the first polymer layer arrangement at the further application station

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS20230364844A1Method for manufacturing a tube laminate, tube laminate and tube packaging

Publication Date: 2023.11.16 HUHTAMAKI FLEXIBLE PACKAGING GERMANY GMBH & CO KG

AI summary

A method for forming a multi-layer packaging laminate including the following steps in the mentioned order:i) providing a polyolefin film as a base layer of the laminate, wherein the base layer forms a first outer most polymer surface of the laminate,ii) applying a first polymer layer arrangement in a flowable state onto the base layer at a first application station, the first polymer layer arrangement having at least one polymer layer,iii) transporting the base layer with the applied first polymer layer arrangement to a further application station,iv) applying a second polymer layer arrangement onto the first polymer layer arrangement at the further application station, the second polymer layer arrangement having at least one polymer layer, wherein the second polymer layer arrangement forms a second outermost polymer surface of the laminate, wherein at least one of the first and the second polymer layer arrangement contains a water vapor and/or oxygen transmission polymer barrier layer, wherein the second polymer layer arrangement is applied to the first polymer layer arrangement in a flowable state.