Multilayer Polyester Film Noise Reduction via Segmentation
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Solution Overview
Problem
Polylactide resin-based films produce loud noise when used as packaging materials, which is a barrier to their commercialization due to noise pollution concerns and consumer dissatisfaction, and blending with aliphatic-aromatic copolyesters compromises transparency and mechanical strength.
Innovation Solution
A multilayer polyester film is developed with alternating layers of polylactic acid-based resin and aliphatic-aromatic copolyesters, specifically polybutylene adipate-co-terephthalate, to reduce noise levels and maintain transparency and mechanical strength, incorporating inorganic particles and a skin layer for improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polylactic acid is blended with aliphatic-aromatic copolyesters to give flexibility to the film, then flexibility is improved, but transparency is remarkably degraded
Solution Approach 1:
The film is divided into multiple thin layers (10-50 layers) of alternating polylactic acid and aliphatic-aromatic copolyester materials. Each layer is thin enough to maintain transparency while the alternating structure provides flexibility. This segmentation allows both materials to contribute their advantages without the negative effects of bulk blending.
Solution Approach 2:
The invention creates a composite multilayer film structure combining polylactic acid and aliphatic-aromatic copolyester in alternating layers. This composite structure leverages the biodegradability and transparency of polylactic acid while incorporating the flexibility of aliphatic-aromatic copolyester, achieving a balance that neither material could provide alone.
2Ease of operation
If polylactic acid is blended with aliphatic-aromatic copolyesters to give flexibility to the film, then flexibility is improved, but mechanical strength is degraded
Solution Approach 1:
The film structure segments the two materials into alternating thin layers rather than bulk blending. This allows the polylactic acid layers to maintain mechanical strength while the aliphatic-aromatic copolyester layers provide flexibility. The layered architecture ensures that the load-bearing function is separated from the flexibility function.
Solution Approach 2:
The multilayer composite structure combines the high mechanical strength of polylactic acid with the flexibility of aliphatic-aromatic copolyester. Each material performs its strength function independently in its own layer, creating a composite that achieves both flexibility and mechanical strength without the degradation seen in blended systems.
3Object-generated harmful factors
If a multilayer structure with many alternating layers is used, then noise level is reduced, but device complexity increases
Solution Approach 1:
The film is segmented into 10-50 alternating layers of thin polylactic acid and aliphatic-aromatic copolyester. This segmentation into many thin layers creates acoustic damping that reduces noise during use, while the regular alternating pattern maintains manufacturing feasibility and structural regularity.
Solution Approach 2:
The invention changes the thickness parameter of each layer to be very thin (total film thickness 10-50 μm with 10-50 layers), which reduces the noise-generating mass of each individual layer while maintaining the overall film integrity. The cumulative effect of many thin layers provides noise reduction without requiring a thick, complex structure.
Data Source
AI summary
A polyester film includes a laminate including a plurality of first layers and a plurality of second layers alternately stacked on the plurality of first layers. Each of the first layers includes lactic acid residues, and each of the second layers includes terephthalate residues and adipic acid residues. The polyester film has an average equivalent noise level of 78 dB or less from a noise level test for film spinning the polyester film 180 degrees at 800 rpm for 30 seconds or more, and has Young's modulus of 280 kgf/mm2 or less.