Multi-layered Thermoplastic Film with Non-Continuous Bonding
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Solution Overview
Problem
Thermoplastic films used in products like bags and packaging often require strong tensile and tear resistance, but thinner films to reduce material costs compromise strength, leading to undesirable properties.
Innovation Solution
The development of multi-layered thermoplastic films with non-continuous bonding between layers, where the bonds are designed to break before the film tears, allowing for a thinner, stronger film with reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thinner thermoplastic films are used to reduce material costs, then material usage decreases, but film strength and tear resistance deteriorate
Solution Approach 1:
The film is divided into multiple discrete layers that are bonded together at specific locations rather than being a single continuous structure. This segmentation allows the film to maintain strength through multiple load-bearing layers while using less total material.
Solution Approach 2:
The invention uses composite multi-layer structures where different layers provide different functions. The combination of layers with strategic bonding creates a composite material system that achieves superior strength-to-weight ratio compared to monolayer films.
2Strength
If conventional co-extruded films with strong lamination are used, then film strength is improved, but material usage increases
Solution Approach 1:
Instead of providing continuous strong bonding between layers, the invention applies partial bonding only at discrete locations where strength is needed. This partial action approach maintains sufficient film strength while significantly reducing the amount of bonding material and overall film thickness required.
Solution Approach 2:
The bonding between layers is applied locally at specific discrete regions rather than uniformly across the entire film. This local quality approach concentrates bonding resources where they provide maximum strength benefit while minimizing material usage in non-critical areas.
3Quantity of substance
If discrete bonding regions are used between layers, then material usage decreases, but lamination strength may be compromised
Solution Approach 1:
The bonding regions are strategically positioned in advance at locations where stress and tension are most likely to occur during film use. This preliminary placement of bonding ensures that strength is provided exactly where needed before the film is put into service.
Solution Approach 2:
The invention optimizes parameters such as bonding region size, spacing, and distribution pattern to achieve the minimum necessary lamination strength. By carefully controlling these parameters, the film maintains adequate strength while using less material than conventional continuous bonding approaches.
Data Source
AI summary
Methods for creating multi-layered incrementally-stretched and incrementally-laminated bags with increased or maintained strength are described herein. An increased level of strength is achieved by bonding adjacent layers of a multi-layer film together in a manner that the bond strength of the laminated layers is less than a strength of a weakest tear resistance of the individual first and second film layers. The inventors have surprisingly found that such a configuration of light bonding provides increased and unexpected strength properties to the multi-layer film as compared to a monolayer film of equal thickness or a multi-layer film in which the plurality of layers are tightly bonded together.