Functionalized Ethylene-Alpha-Olefin Film for Paper Lamination
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Solution Overview
Problem
Current polymeric films used for thermal lamination to paper substrates, such as EVA and BOPP/BOPET, face issues like degradation, low adhesion strength, and high lamination temperatures, and are limited by the availability of EVA resins due to production constraints.
Innovation Solution
A multilayer film with a skin layer comprising anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer having a melting point between 50° C. to 89° C., combined with a substrate layer of polypropylene or polyethylene terephthalate, which enhances paper adhesion strength and reduces lamination temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If EVA extrusion coated films are used for thermal lamination to paper, then paper adhesion is improved, but processing temperature must be kept low (below 250°C) to avoid degradation
Solution Approach 1:
The patent changes the chemical composition parameters of the skin layer by using functionalized ethylene/alpha-olefin interpolymers with specific melting points (50-89°C) and controlled functionality (0.02-0.3 wt%), thereby achieving both high adhesion and controlled processing temperature without degradation
Solution Approach 2:
The patent creates a composite film structure with a functionalized ethylene/alpha-olefin interpolymer skin layer (0.02-0.3 wt% functionality) combined with a polypropylene or polyethylene terephthalate substrate layer, where the composite achieves both high paper adhesion and stable processing characteristics
2Stability of the object's composition
If higher melting point PE and MAH grafted PE resins are used in the functional skin layer, then film stability is improved, but paper adhesion strength decreases and lamination temperature increases
Solution Approach 1:
The patent optimizes the melting point parameter of the skin layer resin to be between 50-89°C, which is lower than conventional high melting point resins (>95°C), thereby achieving both adequate film stability and high paper adhesion strength at lower lamination temperatures
Solution Approach 2:
The patent applies local quality by creating a skin layer with specific functionalized ethylene/alpha-olefin interpolymer characteristics (low melting point, controlled functionality) that is optimized for paper adhesion, while the substrate layer provides overall film stability and mechanical strength
3Strength
If EVA resins are used for thermal lamination, then paper adhesion is improved, but resin availability is limited due to autoclave reactor shortages
Solution Approach 1:
The patent replaces the scarce EVA resin with functionalized ethylene/alpha-olefin interpolymer resins that have appropriate melting points and functionality, providing an alternative material source that maintains adhesion performance while overcoming supply constraints
Solution Approach 2:
The patent changes the resin type from EVA to functionalized ethylene/alpha-olefin interpolymer with specifically controlled melting point (50-89°C) and functionality (0.02-0.3 wt%), thereby achieving equivalent or superior adhesion performance while ensuring material availability
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 proposed film structure achieves higher paper adhesion strength and lower lamination temperatures, enabling faster processing and overcoming the limitations of existing technologies.
Implementation Method 1
The present invention relates to a multilayer film comprising a skin layer comprising an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer... which enhances paper adhesion strength
Implementation Method 2
anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer having a melting point in the range of from 50 to 89° C.... lower lamination temperature
Data Source
AI summary
The present invention relates to a multilayer film comprising a skin layer comprising a anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer having a melting point in the range of from 50 to 89° C., wherein the anhydride and/or carboxylic acid is present in an amount of from 0.02 to 0.3 percent by weight of the polyethylene based resin. The multilayer film further comprises a substrate layer comprising a resin selected from the group consisting of polypropylene or polyethylene terephthalate.