Multilayer Polymeric Film Blind Opening Formation
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Solution Overview
Problem
Existing methods for producing perforated films, such as vacuum drawing, pressurized fluid forming, needle punching, and laser perforation, face limitations in terms of hole size, density, film thickness, material compatibility, and processing costs, particularly for thicker films and certain materials like olefins.
Innovation Solution
A polymeric multilayer film with multiple layers and a structured surface that creates blind openings, which can be converted to through openings using a heat source, allowing for greater control over hole size and density, and enabling the use of a wider range of materials and film thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum or pressurized fluid forming is used to create perforations, then hole formation is achieved, but film thickness is limited to less than 100 micrometers and material selection is limited to olefin-based polymers
Solution Approach 1:
The film is divided into multiple layers (first layer, second layer, third layer) with the perforations formed only in the intermediate second layer. This segmentation allows the second layer to be perforated while the first and third layers remain intact, enabling thicker overall film construction while maintaining effective perforation functionality.
Solution Approach 2:
The invention uses a composite multilayer structure where different layers can be made from different materials. The first and third layers can be made from materials suitable for structural integrity and thickness, while the second layer is made from olefin-based polymer suitable for perforation by vacuum or pressurized fluid forming. This composite approach expands both thickness and material versatility.
2Adaptability or versatility
If needle punching is used to perforate films, then thicker films up to 254 micrometers can be processed, but hole density and protrusion control are limited
Solution Approach 1:
By isolating the perforation function to the second layer only, the process achieves better control over hole density and reduces unwanted protrusions. The first and third layers act as stable boundaries that constrain the deformation during needle punching, improving precision while allowing thicker overall film construction.
3Manufacturing precision
If laser perforation is used to create small holes, then hole size can be controlled to less than 50 micrometers and planar surfaces are achieved, but processing speed and cost are reduced
Solution Approach 1:
The multilayer structure with perforations confined to the second layer allows for more efficient processing. The first and third layers provide structural support that enables faster processing speeds while the second layer can be optimized for precise hole formation, achieving a balance between precision and productivity that reduces overall processing cost.
4Ease of operation
If protrusions are created during film perforation, then directional flow control is improved, but fluid drag increases due to elongated holes and increased surface area
Solution Approach 1:
By confining protrusions to only the second layer while maintaining intact first and third layers, the invention creates controlled protrusions that provide directional flow control without excessive surface area exposure. The outer layers act as caps that limit the protrusion effect, reducing fluid drag while maintaining flow directionality.
Solution Approach 2:
The protrusion feature is localized to specific regions (the second layer) rather than affecting the entire film structure. This local quality approach allows protrusions to provide directional control where needed while minimizing overall surface area and fluid drag in other regions.
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
This approach enables the production of perforated films with customizable thickness and hole density, suitable for applications like acoustic absorption, while overcoming the limitations of existing methods by allowing for thicker films and broader material compatibility.
Implementation Method 1
a first roll having a structured surface that imparts indentations through a first major planar surface of the polymeric multilayer film providing blind openings
Implementation Method 2
applying a heat source to a generally opposed second major surface of the polymeric multilayer film, wherein the application of heat from the heat source results in at least of the blind openings becoming through openings
Data Source
Figure 1~1C
Figure 2~2A
Figure 2B
AI summary
Polymeric multilayer film having first and second generally opposed major surfaces, and comprising first, second, and third layers, an array of blind openings between the first and second major surfaces, and an average thickness, wherein the first, second, and third layers each have a first average thickness excluding any thickness said first, second, and third layers having in any of the blind openings, wherein the first and second layers extend into the first average thickness of the third layer, wherein each of the first, second, and third layers each have a second average thickness (including a thickness of zero) in the blind holes, wherein the second average thickness of the first and third layers are each greater than zero, and wherein the ratio of the first average thickness of the second layer to the second average thickness of the second layer is at least 2.1; and method of making the same. Embodiments of polymeric multilayer film described herein are useful, for example, for acoustic absorption.