Multilayer Polyethylene Film Core Composition for Low-SIT Packaging
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Solution Overview
Problem
Existing polyethylene films made from recycled materials often suffer from inferior mechanical and optical properties, limited impact strength, and poor sealing performance, making them unsuitable for high-quality packaging applications.
Innovation Solution
A multilayer polyethylene film design comprising a core layer made from recycled polyethylene, combined with specific multimodal ethylene terpolymer and polyethylene components, ensuring improved mechanical and optical properties, and low seal initiation temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If recycled polyethylene is used in multilayer films, then environmental sustainability is improved, but mechanical properties and impact strength deteriorate
Solution Approach 1:
The patent creates a composite core layer composition combining recycled polyethylene (40-80 wt%) with virgin polyethylene (20-60 wt%). This composite structure allows the film to achieve both environmental sustainability through recycled content and adequate mechanical properties through the synergistic effect of the polymer blend, where the virgin polyethylene compensates for the weaknesses of recycled material while maintaining the environmental benefits.
Solution Approach 2:
The patent optimizes specific parameters of the recycled polyethylene including melt flow rate (MFR2: 0.1-2.0 g/10 min), density (910-930 kg/m³), and molecular weight distribution (MWD: 2.0-7.5). By controlling these parameters, the patent ensures that the recycled polyethylene maintains compatibility with virgin polyethylene and achieves desired mechanical properties while maximizing environmental sustainability.
2Adaptability or versatility
If recycled polyethylene is used in high amounts, then environmental sustainability is improved, but optical properties and sealing performance deteriorate
Solution Approach 1:
The patent uses a composite core layer with controlled composition ratios where recycled polyethylene (40-80 wt%) is combined with virgin polyethylene (20-60 wt%). This composite approach maintains optical clarity and sealing performance even at high recycled content levels by leveraging the superior properties of virgin polyethylene to compensate for defects in recycled material.
Solution Approach 2:
The patent strictly controls the MFR2 (0.1-2.0 g/10 min), density (910-930 kg/m³), and MWD (2.0-7.5) parameters of recycled polyethylene to ensure optimal performance. These parameter optimizations enable high recycled content (up to 80 wt%) while maintaining adequate optical properties and sealing performance for packaging applications.
3Quantity of substance
If recycled polyethylene is used, then cost reduction is achieved, but mechanical properties and customer requirements deteriorate
Solution Approach 1:
The patent creates a value-added composite material by blending recycled polyethylene (40-80 wt%) with virgin polyethylene (20-60 wt%). This composite approach allows cost reduction through recycled content while maintaining mechanical properties and customer requirements through the synergistic effect of the blend, where virgin polyethylene enhances the performance of recycled material.
Solution Approach 2:
The patent optimizes the MFR2 (0.1-2.0 g/10 min), density (910-930 kg/m³), and MWD (2.0-7.5) parameters of recycled polyethylene to ensure the final product meets customer requirements. These parameter controls enable high recycled content (maximizing cost reduction) while maintaining adequate mechanical properties for packaging applications.
Data Source
AI summary
The invention relates to a multilayer polyethylene film comprising a skin layer, a sealant layer and a core layer located between the skin layer and the sealant layer, wherein the core layer comprises a core layer composition, the core layer composition comprising a recycled polyethylene having an MFR2 of 0.1 to 2.0 g/10 min determined according to ISO 1133 and a density of 910 to 930 kg/m3 determined according to ISO 1183, a multimodal ethylene terpolymer having an MFR2 of 0.5 to 2.0 g/10 min determined according to ISO 1133 and a density of 910 to 930 kg/m3 determined according to ISO 1183, and a polyethylene having an MFR5 of 0.1 to 2.5 g/10 min determined according to ISO 1133 and a density of 925 to 950 kg/m3 determined according to ISO 1183. The invention further relates to a process for producing the multilayer polyethylene film, the use of the core layer composition as a core layer in a multilayer polyethylene film for improving the haze and the SIT of the multilayer polyethylene film and an article comprising the multilayer polyethylene film.