Multi-layer Thermoplastic Film with Interstitial Odor Control
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Solution Overview
Problem
Thermoplastic films used in products like trash bags struggle to effectively control odor permeation while minimizing material usage, as thinner films are more permeable and costly materials are sought to be reduced, leading to a trade-off between odor control and manufacturing costs.
Innovation Solution
A multi-layer thermoplastic film design featuring a first and second film of thermoplastic material with an odor control component positioned between or on them, allowing for reduced overall mass without compromising odor control performance, achieved through coextrusion and discontinuous bonding to trap malodorant molecules and release odor-controlling substances effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of thermoplastic film is increased to improve odor control performance, then the ability to trap malodorant molecules is improved, but the manufacturing cost increases due to higher material usage
Solution Approach 1:
The patent applies composite materials by combining multiple thermoplastic film layers with different properties and incorporating odor control additives within the layered structure. This allows the system to achieve effective odor control through the synergistic interaction of multiple materials rather than relying on a single thick film, thereby reducing overall material usage while maintaining or improving odor control performance.
Solution Approach 2:
The patent implements nesting by placing odor control components and additional film layers within the structure of the trash bag, creating a nested multi-layer configuration. This allows odor control functionality to be embedded within the bag structure itself, enabling effective odor management with thinner overall material usage compared to a single thick film approach.
2Quantity of substance
If the thickness of thermoplastic film is decreased to reduce manufacturing cost, then the material usage is reduced, but the permeability to malodorant molecules increases leading to worse odor control
Solution Approach 1:
The patent uses composite materials to compensate for reduced film thickness. By combining multiple thinner layers with odor control additives and functional coatings, the system achieves effective odor control that would not be possible with a single thin film, thus reducing material usage while maintaining reliability.
Solution Approach 2:
The patent applies local quality by concentrating odor control functionality in specific regions or layers within the multi-layer structure, such as placing odor-absorbing materials at strategic positions or incorporating fragrance layers where they are most effective. This allows thin films to achieve effective odor control through localized enhancement rather than uniform thickness throughout.
3Quantity of substance
If stretched film is used to increase surface area and reduce material usage, then the manufacturing cost is reduced, but the permeability to malodorant molecules increases worsening odor control
Solution Approach 1:
The patent combines stretched film with odor control additives and multiple functional layers to compensate for the increased permeability inherent in stretched materials. The composite structure includes barriers and odor-trapping components that counteract the higher permeability, allowing the use of stretched film for cost and material efficiency while maintaining odor control performance.
Solution Approach 2:
The patent utilizes porous or microstructured materials within the multi-layer construction that can trap and retain malodorant molecules even when the base film is stretched and more permeable. These porous structures provide additional pathways for odor control that are independent of the base film's permeability characteristics.
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 multi-layer film provides enhanced odor control by absorbing and trapping malodorant molecules, maintaining freshness and reducing material usage, thus offering cost savings without degrading odor control properties compared to thicker single-layer films.
Implementation Method 1
The multi-layer film provides enhanced odor control by absorbing and trapping malodorant molecules
Implementation Method 2
a trash bag's ability to control malodorant molecules' permeation through the sidewalls of the trash bag is normally understood to be a function of the thickness of the film used as the sidewalls
Data Source
AI summary
A multi-layer thermoplastic film includes a first film of thermoplastic material, a second film of thermoplastic material bonded to the first film, and an odor control component disposed between the first film and the second film. A method of manufacturing a multi-layer thermoplastic film coextruding a plurality of layers to form a first film, coextruding a plurality of layers to form a second film, disposing at least one odor control component on at least one of the first film and the second film, and bonding the first and second films together such that the at least one substance is disposed between the first film and the second film.