Multi-layer film puncture resistance via composite segmentation
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Solution Overview
Problem
Conventional multi-layer films used for packaging food products are prone to puncture during filling and transportation, which can lead to leakage and contamination, especially when handling sharp-edged food items.
Innovation Solution
A multi-layer film structure comprising a seal layer, a puncture-resistant layer, and a skin layer, where the puncture-resistant layer interconnects the skin and seal layers, utilizing materials like nylon, LLDPE, HDPE, and polypropylene to minimize puncture risks, and ionomer materials for enhanced durability and barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-layer films are used for packaging, then the structure is simple and easy to manufacture, but the films are prone to puncture during filling and transportation
Solution Approach 1:
The patent applies composite materials by creating a multi-layer film structure where each layer has distinct properties: a puncture-resistant layer (containing high-density polyethylene and nylon) provides mechanical strength, a skin layer (containing polypropylene) provides barrier properties, and a seal layer (containing ionomer and polyethylene) provides sealing capability. This composite structure resolves the contradiction by combining materials with complementary properties to achieve both puncture resistance and functional performance.
Solution Approach 2:
The patent applies segmentation by dividing the film into multiple functional layers, each optimized for specific purposes. The puncture-resistant layer is separated from the skin and seal layers, allowing each segment to perform its specialized function. This segmentation enables the film to achieve high puncture resistance without compromising other essential functions like barrier properties and sealability.
2Reliability
If the puncture-resistant layer is added to prevent punctures, then the reliability improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies merging by integrating the puncture-resistant layer with the skin and seal layers into a single co-extruded multi-layer film structure. This combination allows all functional layers to be manufactured simultaneously in one continuous process, achieving high puncture resistance while maintaining manufacturing efficiency. The layers are bonded together through co-extrusion, eliminating the need for separate assembly steps.
3Reliability
If multiple layers are used to prevent puncture, then the puncture resistance increases, but the film thickness and weight increase
Solution Approach 1:
The patent applies local quality by concentrating puncture-resistant materials (high-density polyethylene and nylon) specifically in the puncture-resistant layer that directly contacts sharp-edged food items. Other layers use materials optimized for their specific functions with appropriate thicknesses. This localized approach to material selection and thickness optimization achieves high puncture resistance while minimizing overall film weight.
Data Source
AI summary
A multi-layer film includes a skin layer and a seal layer. The multi-layer film may be used to form a package for a food product.