Non-Continuously Laminated Thermoplastic Films via Post-Extrusion Bonding
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Solution Overview
Problem
Thermoplastic films with varying strength parameters are challenging to combine effectively due to opposing properties, leading to films that are limited by the weakest layer, and the high cost of thermoplastic materials necessitates thinner films which are weaker and less suitable for products requiring strength.
Innovation Solution
Non-continuously laminated structures of thermoplastic films are created by co-extruding individual films with different compositions and then bonding them post-extrusion, allowing for unique combinations of functional benefits like scuff resistance, toughness, and high tensile strength without being limited by the weakest layer, using techniques such as ring rolling and ultrasonic bonding to create light bonds that absorb forces before failing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If co-extruded films use strong lamination between layers to ensure adequate film strength, then delamination is avoided, but films with disparate properties resist bonding during co-extrusion and layers with differing shrink rates cause the co-extruded film to curl
Solution Approach 1:
The patent segments the lamination process into two distinct stages: (1) co-extrusion of layers with moderate bonding to allow disparate materials to bond without excessive shrink rate conflicts, and (2) post-extrusion heat treatment that provides additional bonding and strength. This segmentation allows each stage to be optimized independently, resolving the contradiction between achieving adequate lamination strength and avoiding bonding resistance during co-extrusion.
Solution Approach 2:
The patent applies preliminary bonding during co-extrusion to create a stable multi-layer structure, then follows with post-extrusion heat treatment to enhance bonding strength. This preliminary action ensures layers remain bonded during handling and processing, while the subsequent heat treatment provides the additional strength needed without requiring excessive bonding during the sensitive co-extrusion phase.
2Quantity of substance
If manufacturers use thinner films to reduce material cost, then production costs decrease, but the films become weaker and less suitable for products requiring strength
Solution Approach 1:
The patent creates composite multi-layer films where each layer is made from different thermoplastic materials with complementary properties. By combining materials such as polyethylene, polypropylene, and other polymers in specific configurations, the resulting composite film achieves superior strength and performance characteristics that exceed what could be obtained from a single material, even at reduced thickness.
Solution Approach 2:
The patent assigns different materials to different layers based on their specific functional requirements. Each layer is optimized for its local function (e.g., barrier properties, flexibility, strength), allowing the overall film structure to achieve high performance with minimal total material usage. This local optimization enables thinner overall film thickness while maintaining or enhancing strength.
3Adaptability or versatility
If co-extruded films include layers with varying strength parameters, then diverse functional properties are achieved, but the layer with the weakest strength parameter controls the overall strength of the co-extruded film
Solution Approach 1:
The patent merges multiple layers with different strength parameters into a unified multi-layer structure where the weakest layer is supported and reinforced by adjacent stronger layers. The post-extrusion heat treatment process enhances the bonding between layers, creating a composite structure where the overall strength exceeds that of the weakest individual layer, as the load is distributed across all layers rather than being concentrated in the weakest point.
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 creation of films with enhanced strength and functional benefits, such as increased tensile strength and tear resistance, while reducing material usage, allowing for thinner films with improved performance compared to monolayer or co-extruded films.
Implementation Method 1
using techniques such as ring rolling and ultrasonic bonding to create light bonds that absorb forces before failing
Data Source
AI summary
A non-continuously laminated structure of thermoplastic films comprises thermoplastic films with differing material compositions and differing functional benefits. In particular, one or more embodiments comprise thermoplastic films that are co-extruded separately and then combined together by a post-extrusion bonding process. The differing composition of the various films of the non-continuously laminated structure of thermoplastic films and the post-extrusion bonding process, provide the structures with the functional benefits of the individual films.