Machine-Direction Oriented Multilayer Film for Oxygen Moisture Barrier
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Solution Overview
Problem
Existing polymeric films lack effective barrier properties and structural integrity for packaging sensitive products, particularly in terms of moisture and oxygen protection, and there is a need for improved manufacturing processes to enhance film properties and functionality.
Innovation Solution
A multilayer film structure incorporating a barrier layer, such as ethylene-vinyl alcohol copolymer (EVOH) or polyamide, with a core layer of polyethylene, and optional metal coating, produced through blocked or non-blocked film-manufacturing processes that include extrusion, blowing, and orienting to achieve machine direction orientation, allowing for enhanced barrier and structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer polyethylene film is used, then the manufacturing process is simple and cost-effective, but the barrier properties against moisture and oxygen are insufficient
Solution Approach 1:
The patent applies composite materials by creating a multilayer film structure combining polyethylene core layers with polyamide barrier layers. This composite structure integrates the advantages of each material: polyethylene provides structural integrity and flexibility, while polyamide layers provide superior barrier properties against moisture and oxygen, thereby resolving the contradiction between simple structure and effective barrier protection.
Solution Approach 2:
The patent segments the film into multiple functional layers with distinct roles. The polyethylene core layers provide structural support and flexibility, while the polyamide barrier layers provide protection against moisture and oxygen. This segmentation allows each layer to optimize its specific function, achieving effective barrier properties without requiring a completely complex new structure.
2Reliability
If a multilayer structure with barrier layers is implemented, then barrier properties are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the manufacturing of multiple layers into a single co-extrusion process. By combining the extrusion of polyethylene core layers and polyamide barrier layers in one integrated operation, the patent achieves multilayer film production without requiring separate manufacturing steps for each layer, thereby maintaining ease of manufacture while improving barrier properties.
Solution Approach 2:
The multilayer film structure serves multiple functions simultaneously: the polyethylene core layers provide structural integrity and flexibility, while the polyamide layers provide barrier protection. This multi-functionality is achieved within a single film product, eliminating the need for separate structural and barrier films, thus simplifying the overall manufacturing process despite the increased complexity of the film structure.
3Reliability
If metal coating is applied to enhance barrier properties, then protection against moisture and oxygen is improved, but the film structure and processing become more complex
Solution Approach 1:
The patent uses composite materials by combining polyethylene and polyamide in a multilayer structure, achieving effective barrier properties through material composition rather than metal coating. This approach provides the necessary protection against moisture and oxygen while avoiding the structural complexity and processing challenges associated with metallized films.
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 multilayer film provides improved barrier properties against moisture and oxygen, enhancing the protection of packaged products, and the manufacturing processes enable flexible production of films suitable for various packaging applications.
Implementation Method 1
The barrier layer is arranged to provide a barrier to penetration by molecules
Implementation Method 2
a tie layer arranged to extend between and interconnect the barrier layer and the core layer
Implementation Method 3
an extruding operation in which molten plastics materials are extruded through a die to form a molten tubular film
Implementation Method 4
a blowing operation in which the molten tubular film is blown to expand and establish a blown film
Implementation Method 5
orienting and stretching the blown film in a direction to provide a machine direction oriented film
Data Source
AI summary
A formulation and method for producing a multilayer film and a coated multilayer film comprising a barrier layer including a polar polymer resin, such as EVOH, as described.