Laminating Polyester Film to Metal Strip
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Machine direction oriented (MDO) polyester films are prone to wrinkling and creasing during lamination processes, leading to defective products and high rejection rates, while biaxially oriented films are more expensive and inflexible, and require significant capital expenditure for production.
Innovation Solution
Applying a specific combination of film tension and process line speed to MDO polyester films before the lamination nip, with tension in the longitudinal direction of the film prior to entering the nip, effectively preventing wrinkling and creasing, and allowing for flexible production with relatively inexpensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If machine direction oriented (MDO) polyester films are used in lamination processes, then production costs are reduced and equipment flexibility is improved, but the films are prone to wrinkling and creasing during processing
Solution Approach 1:
The patent applies a specific tension range (0.1-5.0 N/cm, preferably 0.3-3.0 N/cm) to the MDO film before lamination, and controls the lamination temperature within a specific range (80-120°C). These parameter changes stabilize the highly anisotropic film structure, preventing wrinkling and creasing while maintaining the use of cost-effective MDO films instead of expensive biaxially oriented films.
2Manufacturing precision
If biaxially oriented films are used in lamination processes, then film stability and dimensional stability are improved, but production costs increase and equipment flexibility decreases
Solution Approach 1:
The patent changes the processing parameters specifically for MDO films by applying a controlled tension (0.1-5.0 N/cm) and using a specific lamination temperature range (80-120°C). This allows MDO films to achieve the same stability as expensive biaxially oriented films, eliminating the need for costly pre-oriented films while maintaining manufacturing precision.
Solution Approach 2:
The patent applies tension to the MDO film in advance, before the lamination step, to pre-stabilize the highly anisotropic film structure. This preliminary action prevents wrinkling and creasing during subsequent processing, allowing the use of flexible MDO films without sacrificing dimensional stability.
3Device complexity
If MDO films are used without specific tension control, then equipment simplicity is maintained, but wrinkling and creasing occur leading to high rejection rates
Solution Approach 1:
The patent introduces a simple but effective parameter control: applying a specific tension range (0.1-5.0 N/cm) to the MDO film before lamination. This simple parameter change, combined with controlled lamination temperature (80-120°C), effectively prevents wrinkling and creasing without requiring complex equipment modifications, thus maintaining equipment simplicity while dramatically improving product reliability.
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 eliminates wrinkling and creasing issues in MDO films, enabling the production of a wide variety of laminated materials in an economically feasible process with improved stability and reduced production costs.
Implementation Method 1
a tension is exerted on the polyester film in the longitudinal direction of the film between last roll before the lamination roll and the entry side of the lamination nip prior to forming of the laminate
Implementation Method 2
A proper adhesion between the polymer film and the substrate is achieved by heat sealing of the polymer coating film onto the metallic substrate, wherein the film and/or the substrate may be heated to promote the heat sealing
Data Source
Figure 1
Figure 2~3
AI summary
This invention relates to a process for laminating a polyester film onto a major surface of a metal strip and to a laminated metal strip produced thereby, or a can produced therefrom.