Multilayer Film Microparticles Vacuumization Embossing
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Solution Overview
Problem
Existing multilayer films for vacuum packaging require additional expensive steps and specific tools for embossing, which increases manufacturing costs and complexity, and may damage the film or alter its properties.
Innovation Solution
A multilayer film with a thermoplastic mono or multilayer base layer and a thermoplastic heat-sealable layer, incorporating microparticles that enhance the Mean Roughness Depth (Rz) of the first external surface, allowing for effective vacuumization without the need for embossing or additional expensive processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If embossing is used to create channels or dimpled surface on polymeric film for vacuumization, then air removal efficiency is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The microparticles are incorporated into the film during the extrusion process, creating the vacuumization channels in advance before the film is used for packaging. This preliminary action eliminates the need for subsequent embossing operations while ensuring the channels are already in place to facilitate air removal during vacuumization.
Solution Approach 2:
The mechanical embossing process is replaced by incorporating microparticles during extrusion. Instead of using mechanical pressure to create dimpled surfaces, the invention uses particle incorporation during the extrusion process to create similar vacuumization channels, thereby eliminating complex embossing equipment and operations.
2Productivity
If embossing is used to create channels or dimpled surface on polymeric film for vacuumization, then air removal efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The vacuumization channel creation process is merged with the film extrusion process itself. By incorporating microparticles during extrusion, the invention combines two functions (film formation and channel creation) into a single process step, eliminating the need for separate embossing operations and reducing overall manufacturing cost.
Solution Approach 2:
The invention uses inexpensive microparticles that can be easily incorporated during extrusion, replacing expensive embossing equipment and complex manufacturing processes. The microparticles serve as temporary structures during manufacturing but become permanent features in the final film that enable vacuumization.
3Productivity
If embossing is used to create channels or dimpled surface on thin films for vacuumization, then air removal efficiency is improved, but film integrity may be damaged
Solution Approach 1:
The vacuumization channels are created in advance during the extrusion process before the film is formed and sealed. This preliminary action ensures that the channels are created without subjecting the thin film to subsequent mechanical embossing that could damage its integrity or cause tearing.
Solution Approach 2:
The mechanical embossing system that could damage thin films is replaced by a particle incorporation method during extrusion. This substitution eliminates the need for high-pressure mechanical embossing that risks damaging film integrity, while still achieving effective vacuumization channels.
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 multilayer film achieves enhanced ability to be emptied and vacuumized, with a strong seal and robust packaging, while maintaining film integrity and reducing manufacturing costs and complexity.
Implementation Method 1
microparticles at least in part incorporated in at least one of said heat-sealable layer (A) and said mono or multilayer base layer (B), wherein one or more regions of said first external surface present a Mean Roughness Depth (Rz) of at least 4.5 μm
Implementation Method 2
a thermoplastic heat-sealable layer (A) adhered to the base layer (B)
Data Source
AI summary
It is described a multilayer film for packaging, optionally for vacuum packaging, the multilayer film having a first external surface destined to contact a product hosted in the package and a second external surface opposite to the first external surface, wherein the multilayer film comprises a thermoplastic mono or multilayer base layer (B), a thermoplastic heat-scalable layer (A) adhered to the base layer (B), and microparticles incorporated in the heat-scalable layer (A) and in the mono or multilayer base layer (B); the microparticles are positioned and configured to confer to the first external surface of the multilayer film a Mean Roughness Depth (Rz) of at least 4.5 μm, measured according to ISO4287. A package and a process of packaging using the above multilayer film are also disclosed.