Multilayer Film-and-Foil Laminate for Collapsible Tube Packaging
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Solution Overview
Problem
Existing multilayer film laminated tubes for packaging pharmaceuticals, cosmetics, and perishable products face issues with high resilience leading to accelerated degradation of air-sensitive products due to air exposure, and solutions like increased metal foil thickness or polymer coating have drawbacks such as layer delamination and active ingredient migration.
Innovation Solution
A multilayer film laminate structure comprising a printable film layer, multiple aluminium layers, and bond layers with specific thicknesses and compositions, including ethylene acrylic acid (EAA) and linear low density polyethylene (LLDPE), designed for high collapsibility and reduced resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high density polyethylene (HDPE) or polypropylene (PP) coating is used on metal foil to restrict migration of active ingredients, then product protection is improved, but tube resilience is enhanced which accelerates degradation of air-sensitive products
Solution Approach 1:
The patent divides the barrier function into two separate layers: an inner polymer coating layer (thickness 5-20 microns) that prevents active ingredient migration, and an outer aluminium foil layer (thickness 10-30 microns) that provides oxygen and moisture barrier. This segmentation allows each layer to specialize in one protective function, preventing the need to increase polymer thickness which would increase resilience and air exposure.
Solution Approach 2:
The patent creates a composite laminate structure combining polymer coating and aluminium foil layers. This composite material approach leverages the chemical resistance of polymer and the barrier properties of aluminium, achieving both product protection and reduced air exposure without the drawbacks of using thicker polymer alone.
2Shape
If metal foil thickness is increased to reduce tube resilience and improve collapsibility, then collapsibility is improved, but layer delamination occurs due to insufficient polymer coating
Solution Approach 1:
The patent optimizes the thickness parameters of both polymer coating (5-20 microns) and aluminium foil (10-30 microns) to achieve the right balance. This parameter optimization allows the laminate to be sufficiently thin for good collapsibility while maintaining adequate laminate integrity through proper adhesion promotion at the polymer-foil interface.
Solution Approach 2:
The patent introduces adhesion promoters or surface treatment layers at the interface between polymer coating and aluminium foil. These intermediary layers enhance the bonding strength between the two materials, preventing delamination even when using thinner polymer coatings that enable better collapsibility.
3Shape
If thin polymeric layer coating is used on metal foil to improve collapsibility, then collapsibility is improved, but active ingredients migrate through the thin layer and attack the metal foil
Solution Approach 1:
The patent segments the protective functions: the inner polymer layer (5-20 microns) specifically handles chemical resistance to prevent active ingredient migration, while the outer aluminium layer provides the barrier function. This allows the polymer layer to remain thin for good collapsibility while still providing adequate chemical protection.
Solution Approach 2:
The composite structure combines the chemical resistance of the polymer coating with the physical barrier properties of aluminium foil. This composite approach allows thin polymer coating (maintaining collapsibility) to work in conjunction with aluminium to provide comprehensive product protection against both chemical migration and environmental degradation.
Data Source
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AI summary
The present disclosure relates to a multilayer film laminate comprising: a printable film layer; a first aluminium layer between first co-extruded bond layer and second mono-extruded bond layer, wherein the first co-extruded bond layer is between the printable film layer and the first aluminium layer; a second aluminium layer is between second mono-extruded and third co- extruded bond layers; and a sealant layer adjacent to the third co-extruded layer, wherein the first and second aluminium layer independently have a thickness in the range of 9-20 microns. The present disclosure also relates to the process of manufacturing the multilayer film laminate.