Multi-layer film with embedded tacky layer for reclosable packaging
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Solution Overview
Problem
Existing reclosable film packages require multiple adhesives, laminating steps, and pressure-sensitive labels, leading to increased costs and complexity in manufacturing, and often necessitate high force for initial opening, which can be difficult for consumers to apply and control.
Innovation Solution
A multi-layer film with an embedded tacky layer and a release layer, where the tacky layer is encapsulated between outer and inner film layers, allowing for a single adhesive type between webs and enabling easy opening and resealing without separate reclosure labels, using a single-step coextrusion process to reduce costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple adhesives, deadening agents, or labels are used during lamination or label application to create reclosable packages, then the reclosable function is achieved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The patent combines the reclosable adhesive function and the structural film layers into a single coextruded multi-layer film. The adhesive layer is integrated within the film structure itself, eliminating the need for separate adhesive application steps, deadening agents, or reclosure labels. This merging of functions reduces manufacturing complexity while maintaining the reclosable feature.
Solution Approach 2:
The multi-layer film structure serves multiple functions simultaneously: the outer and inner films provide structural integrity, the integrated adhesive layer provides reclosable functionality, and the coextrusion process ensures uniform adhesive distribution. This multi-functional design eliminates the need for separate components like reclosure labels or additional adhesive applications.
2Reliability
If traditional heat seals are used to provide package reclose feature, then the reclosable function is achieved, but a large amount of force is required for initial opening, which is difficult for consumers to apply and control
Solution Approach 1:
The patent changes the adhesive parameters by using a pressure-sensitive adhesive with controlled tack properties instead of traditional heat seals. The adhesive is formulated to provide sufficient bond strength for sealing while allowing easy separation with minimal force. The coextrusion process ensures uniform adhesive distribution, creating a seal that is strong when closed but easy to open by simply peeling apart the films.
Solution Approach 2:
The patent uses a composite multi-layer film structure where different materials are coextruded to achieve specific properties. The adhesive layer is formulated as a pressure-sensitive adhesive with controlled tack, combined with outer and inner film layers. This composite structure provides both strong sealing capability and easy opening, eliminating the need for high force required by traditional heat seals.
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 solution allows for easy and controlled opening and resealing of packages with reduced force requirements, eliminating the need for multiple adhesives and labels, while maintaining the integrity and resealability of the package, thus simplifying the manufacturing process and enhancing user convenience.
Implementation Method 1
an outer film portion including an embedded tacky layer, and an inner film portion. At least a portion of the film can be formed via a single step, multi-layer coextrusion
Implementation Method 2
At least a portion of the film can be formed via a single step, multi-layer coextrusion, which avoids the costs and extra steps of a lamination process
Data Source
AI summary
A multi-layer film and a film package made from the film are described herein that provide resealing capabilities by utilizing a tacky layer within the multi-layer film. The multi-layer film can include an outer film portion including the embedded tacky layer and an inner film portion. An opening feature formed in the multi-layer film includes a flap configured to be manipulated by a user to create an opening through the multi-layer film. The inner film portion can include a release layer configured specifically to interact with the tacky layer to provide a desired separation peel force and resealing functionalities. The outer film portion can include an outer film layer disposed on an opposite side of the tacky layer from the release layer that is configured to permanently adhere to the tacky layer.