Multi-layered Airbag Films with Thin Gas-barrier Layers
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Solution Overview
Problem
Multi-layered films with gas-barrier properties used in applications like airbags and footwear face issues with cracking and increased gas transmission rates due to flexing, leading to reduced durability and transparency, with existing solutions either increasing material quantity or thickness, which are not effective in preventing crack formation.
Innovation Solution
The use of thinner gas-barrier layers with average thicknesses of less than 0.75 micrometers and a lower number of layers, such as 24 or 30, alternating with elastomeric layers, which reduces cracking and maintains gas retention properties without increasing overall material quantity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of gas-barrier layers or their thickness is increased to maintain gas retention properties, then gas transmission rate increases, but the film becomes more prone to cracking and loses durability under flexing conditions
Solution Approach 1:
The patent applies parameter changes by precisely controlling the thickness of each gas-barrier layer to be between 0.01-10 micrometers and the number of layers to be 1-100, creating an optimized multi-layer configuration that achieves both gas retention and crack resistance. This quantitative parameter optimization resolves the contradiction by finding the optimal balance point rather than simply increasing one parameter at the expense of the other.
Solution Approach 2:
The patent employs composite materials by combining multiple gas-barrier layers with different thicknesses and compositions within the multi-layered film structure. This composite approach allows different layers to contribute differently to gas barrier performance and mechanical flexibility, resolving the contradiction between gas retention and crack resistance through material diversity and structural complexity.
2Strength
If thinner gas-barrier layers are used to improve flexibility and reduce cracking, then crack resistance improves, but gas transmission rate increases reducing gas retention
Solution Approach 1:
The patent applies segmentation by dividing the gas-barrier function into multiple discrete layers rather than using a single thick layer. Each thin layer (0.01-10 micrometers) is individually flexible and crack-resistant, while collectively they provide sufficient gas barrier performance. This segmentation resolves the contradiction by distributing the gas barrier function across multiple flexible units.
Solution Approach 2:
The patent uses parameter changes by systematically varying the thickness parameter of individual gas-barrier layers within the 0.01-10 micrometer range, allowing optimization of both flexibility and gas barrier performance. This parametric approach enables fine-tuning of the film properties to simultaneously achieve crack resistance and gas retention.
3Reliability
If more gas-barrier layers are added to maintain gas retention, then gas transmission rate decreases, but the overall material quantity and complexity increase
Solution Approach 1:
The patent applies parameter changes by optimizing the number of gas-barrier layers to fall within 1-100 layers, finding the optimal balance between gas retention performance and structural complexity. This quantitative parameter optimization resolves the contradiction by identifying the minimum necessary layer count to achieve gas barrier function without excessive complexity.
Solution Approach 2:
The patent uses copying by repeating the gas-barrier layer structure multiple times in a standardized pattern throughout the multi-layered film. This modular copying approach simplifies manufacturing while achieving the required gas retention properties, resolving the contradiction between performance and complexity through systematic repetition rather than unique complex structures.
4Strength
If existing solutions increase material quantity or thickness to prevent cracking, then crack resistance may improve, but gas transmission rate increases and durability is not effectively maintained
Solution Approach 1:
The patent employs composite materials by creating a multi-layered structure with alternating gas-barrier layers (0.01-10 micrometers thick) and other functional layers. This composite structure provides crack resistance through the multi-layer architecture itself rather than through increased material quantity, while maintaining gas retention properties. The composite approach resolves the contradiction by using structural complexity rather than material quantity to achieve durability.
Solution Approach 2:
The patent applies parameter changes by optimizing the thickness parameter of gas-barrier layers to be between 0.01-10 micrometers, which is thinner than conventional single layers but provides equivalent or superior crack resistance when used in a multi-layer configuration. This parametric optimization resolves the contradiction by finding the optimal thickness value that balances crack resistance, gas retention, and material efficiency.
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 results in multi-layered films that are more crack-resistant, maintain low gas diffusion rates, and can be used in various shapes and applications with extended durability and clarity, while avoiding the need for increased material usage.
Implementation Method 1
multi-layered films having gas-barrier properties... thin gas-barrier layers, which have been found to increase film flexibility while also retaining good film durability and gas-barrier properties
Data Source
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AI summary
Multi-layered films and methods of manufacturing the multi-layered films are provided. In one aspect, disclosed herein is a method for producing a multi-layered film, the method comprising: co-extruding a gas-barrier material and elastomeric material to form a multi-layered film having a core region that comprises at least 40 gas-barrier layers each comprising the gas-barrier material and each having an average thickness ranging from about 0.5 micrometers to about 2 micrometers; and a plurality of elastomeric layers alternating with the gas-barrier layers, wherein each of the elastomeric layers of the plurality comprises the elastomeric material and each has an average thickness ranging from about 2 micrometers to about 8 micrometers.