Multi-Layer Polymer Fiber Elastic Recovery
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Solution Overview
Problem
Existing elastic monolayer films face challenges such as tackiness leading to 'blocking' during storage, poor aesthetics, and complexity in processing due to the need for multiple heating steps to achieve desired mechanical properties.
Innovation Solution
A fiber comprising 40 wt% to 98 wt% of a low crystallinity polymer and 2 wt% to 60 wt% of a high crystallinity polymer, where the low crystallinity polymer is an ethylene/α-olefin interpolymer with specific molecular characteristics, allowing for plastic deformation and improved elastic recovery, is used to create a pre-stretched, multi-layer film or laminate with a core and skin layer structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If elastic monolayer films are produced to achieve desired elastic properties, then elastic recovery is improved, but tackiness increases causing blocking during storage
Solution Approach 1:
The invention divides the film into multiple layers with distinct functions: an inner elastic layer providing recovery and outer non-tacky layers preventing blocking. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The invention uses composite material structures combining different polymer types (ethylene/α-olefin interpolymer with specific molecular architecture) to achieve both elastic recovery and reduced tackiness in a single integrated film system.
2Strength
If multiple heating steps are used to achieve desired mechanical properties, then elastic recovery is improved, but processing complexity increases
Solution Approach 1:
The invention changes the molecular parameters of the polymer (using ethylene/α-olefin interpolymer with specific comonomer content and molecular weight distribution) to achieve desired mechanical properties without requiring multiple heating steps, thus simplifying processing.
Solution Approach 2:
The desired molecular structure and mechanical properties are built into the polymer during manufacturing, so the film achieves elastic recovery without requiring subsequent heat treatment steps that would add processing complexity.
3Ease of operation
If film surface is embossed or textured to improve feel, then surface area increases, but manufacturing complexity increases
Solution Approach 1:
The invention applies different surface characteristics to different layers: the outer non-tacky layers provide the desired surface feel and aesthetics, while the inner elastic layer provides mechanical recovery, allowing each layer to have optimized local properties.
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 enables the production of films with enhanced elastic recovery and reduced tackiness, improving storage and aesthetic properties while simplifying the processing steps by allowing for substantial elastic recovery and maintaining mechanical strength.
Implementation Method 1
said fiber is capable of undergoing plastic deformation upon elongation
Implementation Method 2
improved elastic recovery
Implementation Method 3
polymer compositions which develop considerable mechanical strength upon cooling by the forming of crystalline phases
Implementation Method 4
mechanical and processing techniques used to emboss or texture the film surface in order to increase the surface area
Data Source
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AI summary
The invention is directed to a fiber comprising a low crystallinity polymer and a high crystallinity polymer, wherein the fiber is capable of undergoing plastic deformation upon elongation and wherein the low crystallinity polymer comprises at least one ethylene/α-olefin inter polymer.