Microporous Plastic Film for Bread Packaging
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Solution Overview
Problem
Conventional plastic films for packaging foods like bread lack sufficient moisture permeability, leading to deterioration in taste and texture, and are expensive to produce, especially when using polyurethane/SBS rubber films with extrusion lamination.
Innovation Solution
A microporous plastic film is created by pressing a plastic film between a pattern roll with high-hardness fine particles and an anvil roll having recesses, resulting in a film with varying recess diameters and depths, enhancing moisture permeability while being cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plastic films are used for packaging bread, then the film provides basic packaging function, but the moisture permeability is insufficient causing deterioration of taste and texture
Solution Approach 1:
The patent applies porous materials by forming micropores with diameters of 0.5-3 mm in the plastic film through mechanical punching or laser processing. These pores enable high moisture permeability while maintaining the integrity of the packaging film, allowing moisture to escape and preventing deterioration of bread quality.
Solution Approach 2:
The patent changes the physical parameters of the plastic film by creating controlled pores with specific diameter ranges (0.5-3 mm) and controlling their distribution. This parameter change transforms the film from a moisture-impermeable barrier to a moisture-permeable packaging material that maintains bread quality.
2Reliability
If large pores are formed in plastic film to increase moisture permeability, then moisture can escape, but the film becomes less effective at maintaining food quality
Solution Approach 1:
The patent applies local quality by creating pores with specific local characteristics - diameters of 0.5-3 mm that are large enough for moisture escape but controlled in size and distribution to maintain overall film integrity. The pores are locally distributed throughout the film rather than concentrated in one area, ensuring uniform moisture permeability while preserving food quality.
3Reliability
If polyurethane/SBS rubber films with extrusion lamination are used to achieve high moisture permeability, then moisture permeability improves, but production cost increases significantly
Solution Approach 1:
The patent applies this principle by using conventional, inexpensive plastic films that can be easily processed with pores. Rather than using expensive specialized materials like polyurethane/SBS rubber composites, the invention uses readily available plastic films with added pore structures, significantly reducing material and production costs while achieving the required moisture permeability.
Solution Approach 2:
The patent replaces complex extrusion lamination processes with simpler mechanical pore-forming methods such as needle punching or laser drilling. This substitution eliminates the need for multi-layer composite structures and complex manufacturing equipment, reducing both production costs and process complexity while achieving high moisture permeability.
4Reliability
If paper bags are used for packaging, then high moisture permeability is achieved, but the contents cannot be seen
Solution Approach 1:
The patent applies composite materials by combining the properties of plastic films (transparency, strength) with pore structures that provide moisture permeability. The resulting composite structure maintains the visual clarity of plastic while incorporating moisture-permeable features, achieving both visibility and moisture control in a single material system.
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 resulting film achieves high moisture permeability, suitable for packaging moisture-vaporizable contents like bread, with adjustable cleft formation for optimal moisture vaporization, ensuring the preservation of food quality and reducing production costs.
Implementation Method 1
pressing a plastic film under pressure through a gap between a pattern roll and an anvil roll
Data Source
AI summary
A high-moisture-permeability, microporous plastic film randomly having a lot of recesses having different opening diameters and depths, with clefts formed in the recesses, is produced by pressing a first pattern roll randomly having a lot of high-hardness, fine particles having sharp edges on a roll body surface to a flat-surface metal roll, to produce an anvil roll randomly having a lot of recesses on a metal roll surface; arranging a second pattern roll randomly having a lot of high-hardness, fine particles having sharp edges on a roll body surface oppositely to the anvil roll; and passing a plastic film through a gap between the second pattern roll and the anvil roll.