Multi-layer Tube Co-extrusion with Cellular Core
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Solution Overview
Problem
Current methods for producing extruded materials, particularly those using polymeric materials, face challenges in minimizing material usage while maintaining structural integrity and insulation properties, especially in forming multi-layer containers where the density of the core layer needs to be optimized for efficient co-extrusion processes.
Innovation Solution
A co-extrusion process forming a multiple layer tube with an inner high-density polymeric layer, a middle low-density insulative cellular non-aromatic polymeric layer, and an outer high-density polymeric layer, where the core layer is made from a formulation comprising high-density polyethylene base resins, nucleating agents, and blowing agents to achieve a density range of 0.3 to 0.5 g/cm3, allowing for minimized material usage and enhanced insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a multi-layer co-extrusion process is used to minimize material usage, then material efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The container wall is segmented into multiple functional layers: an inner layer for structural integrity, a middle cellular layer for insulation, and an outer layer for additional strength. This segmentation allows each layer to be optimized independently for its specific function, achieving material efficiency while maintaining manufacturability through specialized co-extrusion equipment
Solution Approach 2:
The patent employs composite materials by combining different polymeric materials with distinct properties in a single co-extruded structure. The inner and outer layers use materials optimized for mechanical strength, while the middle layer uses a cellular polymer structure optimized for thermal insulation, creating a composite structure that achieves both material efficiency and functional performance
2Temperature
If the core layer density is reduced to enhance insulation, then thermal insulation improves, but structural integrity may deteriorate
Solution Approach 1:
Different regions of the container wall are assigned different densities and material properties: the inner and outer layers maintain high density for structural integrity, while the middle cellular layer uses low density (0.01-0.8 g/cm³) for optimal thermal insulation. This local quality differentiation allows the structure to simultaneously achieve both insulation performance and mechanical strength
Solution Approach 2:
The composite structure combines high-density polymeric materials in the inner and outer layers with a low-density cellular polymer in the middle layer. This composite approach allows the low-density insulation layer to be surrounded by high-strength structural layers, ensuring that the reduced density of the core layer does not compromise overall structural integrity
3Productivity
If the middle cellular layer density is optimized to 0.3-0.5 g/cm3 for efficient co-extrusion, then manufacturing efficiency improves, but insulation performance may be compromised
Solution Approach 1:
The patent identifies and optimizes specific parameter ranges for the cellular layer density (0.3-0.5 g/cm³) that balance manufacturing efficiency and insulation performance. This parameter optimization allows the co-extrusion process to operate efficiently while maintaining adequate thermal insulation, representing a compromise that satisfies both manufacturing and performance requirements
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 process effectively reduces material usage and enhances insulation by optimizing the density of the core layer, enabling the production of lightweight, efficient multi-layer containers with improved structural integrity and thermal insulation.
Implementation Method 1
a middle cellular non-aromatic polymeric material located between the inner and outer polymeric layers
Implementation Method 2
a multiple layer tube in a multiple layer co-extrusion blow molding process
Data Source
AI summary
A vessel is configured to hold a product in an interior region formed in the vessel. The vessel includes an inner layer arranged to define the interior region and an outer layer. The vessel is formed using a blow-molding process in which a multiple layer parison is blow molded to form the vessel. The multiple layer parison is formed in an extrusion process in which a number of extruders are arranged to co-extrude associated inner and outer parisons to establish the multiple layer parison.