Multilayer Film MDO Substrate Polyethylene Blend Recyclability

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Solution Overview

Problem

The packaging industry faces challenges in recycling laminate structures with polyamide substrates and achieving smooth, flat seals in polyethylene laminates without the sealing bar sticking to the laminate surface, leading to compromised operation efficiency.

Innovation Solution

A multilayer film design featuring a machine direction oriented (MDO) substrate with a core layer comprising a blend of polyethylenes of different densities, along with a PTFE coated fabric one-sided adhesive tape for improved sealing and recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polyamide substrate is used in laminate structure, then oxygen and aroma barrier properties are improved, but recyclability deteriorates

Engineering Contradiction:
Improveoxygen and aroma barrierVSAvoidrecyclability
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material composition parameters by replacing polyamide with specific polyethylene blends (LLDPE, LDPE, HDPE) in the substrate layers, transforming the laminate from non-recyclable to recyclable while maintaining barrier properties through alternative material combinations

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material structures with multiple polyethylene types combined in specific layers (e.g., LLDPE in outer layers for strength, LDPE in inner layers for sealability) to achieve both barrier performance and recyclability that single materials cannot provide

Inventive Principle:
Principle #40Composite materials

2Reliability

If conventional polyethylene laminate is used, then sealing performance is achieved, but sealing bar sticking occurs leading to compromised operation efficiency

Engineering Contradiction:
Improvesealing performanceVSAvoidoperation efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent modifies the polyethylene molecular weight parameters and blend ratios to control melt flow characteristics during sealing, ensuring the sealing bar does not stick while maintaining adequate seal strength and smooth seal formation

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies different polyethylene types with specific properties to different layers: LLDPE with higher strength for outer layers, and LDPE with better sealability for inner sealing layers, optimizing local properties for specific functions

Inventive Principle:
Principle #3Local quality

3Strength

If polyamide substrate is used to achieve toughness and stiffness, then mechanical properties are improved, but manufacturing complexity and cost increase

Engineering Contradiction:
Improvetoughness and stiffnessVSAvoidmanufacturing complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent adjusts molecular weight parameters and blend ratios of polyethylene components to achieve mechanical properties comparable to polyamide, simplifying the substrate structure while maintaining required toughness and stiffness

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses homogeneous polyethylene-based materials throughout the substrate structure, eliminating the need for complex multi-material laminations required by polyamide, thereby reducing manufacturing complexity

Inventive Principle:
Principle #33Homogeneity

Data Source

PatentUS11691398B2Multilayer films and methods of making the same
Publication Date: 2023.07.04 EXXONMOBIL CHEMICAL PATENTS INC

AI summary

Disclosed are multilayer films with at least one MDO substrate.