Multilayer Film Coupling Layer Reduces Thickness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multilayer structures that provide reliable and reproducible opening mechanisms and barrier properties are often thick and complex, requiring seven or more layers, which is undesirable for various applications.
Innovation Solution
A multilayer structure comprising a polyolefin sealant layer, a coupling layer with 15-50 weight percent maleic anhydride grafted (MAH) polymer, and a barrier layer directly on the coupling layer, using a blend of polypropylene-based plastomers and low density polyethylene, which allows for cohesive failure and reduces thickness while maintaining barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multilayer structures with seven or more layers are used, then reliable and reproducible opening mechanisms and barrier properties are achieved, but the structure becomes thick and complex
Solution Approach 1:
The patent combines multiple functions into fewer layers by using a coupling layer with maleic anhydride grafted polymer that provides both adhesion and barrier properties, and a polyolefin sealant layer that provides both sealing and controlled failure characteristics. This merging of functions reduces the total layer count from seven or more to just three layers while maintaining reliable and reproducible opening mechanisms.
Solution Approach 2:
The patent employs composite materials in the coupling layer by combining maleic anhydride grafted polymer with polyolefin, creating a material that exhibits both strong adhesion to barrier layers and controlled cohesive failure characteristics. This composite approach allows a single layer to perform multiple functions that traditionally required separate layers.
2Object-affected harmful factors
If traditional multilayer structures with seven or more layers are used, then barrier properties are maintained, but the structure becomes thick
Solution Approach 1:
The patent merges barrier function into the coupling layer by selecting barrier materials that can be directly applied to the MAH-containing coupling layer. This eliminates the need for additional intermediate layers between the coupling and barrier layers, reducing overall thickness while maintaining effective barrier properties against moisture and oxygen.
Solution Approach 2:
The patent applies local quality by concentrating barrier properties in specific layers (the barrier layer directly on the coupling layer) rather than distributing thin barrier functions across multiple layers. The coupling layer's MAH polymer provides localized adhesion quality, while the barrier layer provides concentrated barrier quality, achieving effective protection with reduced total thickness.
3Reliability
If a coupling layer with high MAH polymer content (30-50 weight percent) is used, then cohesive failure is achieved, but the composition becomes more complex
Solution Approach 1:
The patent achieves cohesive failure by changing the compositional parameter of the coupling layer to contain 30-50 weight percent maleic anhydride grafted polymer. This specific parameter range creates the right balance of adhesion and controlled failure characteristics. The complexity is managed by focusing on this key compositional parameter rather than using complex multi-component systems.
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 a multilayer structure to reliably and reproducibly open via cohesive failure, providing desired barrier properties and a thinner profile compared to traditional approaches, with a broad seal window in terms of temperature and pressure, facilitating easier manufacturing and aesthetically consistent openings.
Implementation Method 1
a coupling layer on the polyolefin sealant layer, where the coupling layer includes a polyolefin and a maleic anhydride grafted (MAH) polymer
Implementation Method 2
a polyolefin sealant layer, a coupling layer on the polyolefin sealant layer
Data Source
AI summary
Embodiments relate to multilayer structures, multilayer films, and packages formed therefrom. As an example, a multilayer structure can include a multilayer structure comprising a polyolefin sealant layer, a coupling layer on the polyolefin sealant layer, where the coupling layer includes a polyolefin and a maleic anhydride grafted (MAH) polymer, where the total amount of MAH polymer is from 15 weight percent to 50 weight percent of a total weight percent of the coupling layer, where the polyolefin is selected from the group consisting of a high pressure low density polyethylene, a high density polyethylene, an ethylene acrylic acid copolymer, an ethylene(meth)acrylic acid copolymer, propylene based plastomers, ionomers or a combination thereof, and a barrier layer directly on the coupling layer.