Incrementally Stretched Thermoplastic Films with Ribbed Patterns
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Solution Overview
Problem
Thermoplastic films face challenges in maintaining opacity and haze when stretched, leading to consumer perception of weakness and increased costs due to the need for additives, which also compromise film strength.
Innovation Solution
Implementing a method of incrementally stretching thermoplastic films in the machine direction using cold MD ring rolling to create a ribbed pattern, maintaining or increasing haze while reducing film gauge, thereby reducing material usage without compromising opacity or strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thermoplastic film is stretched to reduce thickness and material usage, then material cost is reduced, but haze and opacity decrease making the film appear weaker
Solution Approach 1:
The patent applies optical property modification by creating a ribbed pattern through incremental stretching that changes how light interacts with the film. The ribbed structure scatters light differently, increasing haze and opacity without requiring pigments or additives, thereby resolving the contradiction between material reduction and optical appearance
Solution Approach 2:
The patent changes the physical structure parameter of the film by applying incremental stretching to create a ribbed pattern. This structural parameter change increases haze and opacity while allowing reduced material usage, as the ribbed structure itself provides the optical properties previously requiring thicker material or additives
2Illumination intensity
If additives such as TiO2 or voiding agents are added to increase opacity of thinner films, then haze is improved, but film strength properties are negatively impacted and production cost increases
Solution Approach 1:
The patent extracts and eliminates the need for opacity-inducing additives like TiO2 and voiding agents by using a mechanical ribbed pattern created through incremental stretching. This structural approach provides haze and opacity intrinsically, removing the harmful additives that compromise film strength while maintaining the desired optical appearance
Solution Approach 2:
The patent replaces expensive additives with a simple structural modification achieved through mechanical stretching. The ribbed pattern, created by a relatively simple process, provides the same optical benefits as costly additives without the negative impact on film strength or increased material cost
3Quantity of substance
If thermoplastic film is stretched to reduce gauge, then material cost is reduced, but consumers perceive the film as weaker
Solution Approach 1:
The ribbed pattern created by incremental stretching modifies the optical appearance of the film, increasing haze and giving it a more substantial visual presence. This visual enhancement addresses consumer perception of strength, making thinner films appear more robust and reliable without requiring actual increases in material gauge
4Illumination intensity
If pigments and additives are used to add color and opacity to thinner films, then haze is improved, but production cost increases
Solution Approach 1:
The patent removes the need for expensive pigments and opacity additives by using a mechanical ribbed structure created through incremental stretching. This structural approach provides inherent opacity and visual interest without the cost of additional materials or complex formulation processes
Solution Approach 2:
The patent replaces costly pigments and additives with a simple structural modification achieved through mechanical stretching. The ribbed pattern provides the same optical benefits as expensive additives but at minimal additional cost, improving the ease of manufacture while maintaining desired opacity
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 method allows for significant material savings by reducing film gauge while maintaining or increasing haze, enhancing consumer perception of film strength and reducing the need for costly additives, thus lowering production costs.
Implementation Method 1
Incremental stretching of thermoplastic film, on the other hand, typically involves running the film between grooved or toothed rollers. The grooves or teeth on the rollers intermesh and stretch the film as the film passes between the rollers.
Implementation Method 2
Haze measures wide angle light scattering, and is a way of quantifying how well one can see contrast through films.
Data Source
AI summary
Methods of increasing the haze of a thermoplastic film include incrementally stretching thermoplastic films in the machine direction. In one or more implementations, methods of incrementally stretching thermoplastic films include reducing the gauge of the films without reducing the films' haze. The methods can involve cold stretching the films and imparting rib patterns into the film. The linear ribs can have alternating thick and thin gauges. Incrementally stretched thermoplastic films can have a haze that is approximately equal to or greater than the haze of the film prior to stretching.