Planar Composite PE Blend Layers for Crease Leakproofness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional packaging systems for foodstuffs, such as cans and glass jars, face issues with high weight, energy-intensive production, and difficulties in opening, leading to potential damage and leaks during storage and use, particularly due to tearing or perforation of polymer layers in creasing regions.
Innovation Solution
A planar composite structure comprising a carrier layer, a barrier layer, and PE blend layers with specific weight percentages and damping factor differences of LDPEa and LDPEt, optimized for stability, leakproofness, and efficient production, including a process for folding and joining to form containers suitable for long-term storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer layers are used in planar composites for containers, then the container can be produced with basic sealing properties, but tearing off or perforation occurs in creasing regions leading to leaks and functional damage
Solution Approach 1:
The patent applies composite materials by combining LDPEa and LDPEt in a specific blend ratio (at least 50 wt.% LDPEt and up to 50 wt.% LDPEa) to create a PE blend layer that exhibits synergistic properties. This composite polymer structure provides both the necessary flexibility for creasing and the strength to prevent tearing and leaking, resolving the contradiction between reliability and strength.
Solution Approach 2:
The patent changes the material parameters by specifying a damping factor difference between -0.3 and -0.6 for the PE blend layer, and controlling the molecular characteristics of LDPEa and LDPEt. These parameter adjustments optimize the material's viscoelastic properties to prevent tearing in creasing regions while maintaining leakproofness.
2Ease of manufacture
If conventional LDPE layers are applied in the production process, then the container can be manufactured, but tearing off of PE layers occurs repeatedly especially in creasing regions causing damage and defects
Solution Approach 1:
The patent changes the material parameters by specifying a damping factor difference between -0.3 and -0.6 for the PE blend layer, and controlling the molecular characteristics of LDPEa and LDPEt. These parameter adjustments optimize the material's viscoelastic properties to prevent tearing in creasing regions while maintaining leakproofness.
Solution Approach 2:
The patent applies composite materials by combining LDPEa and LDPEt in a specific blend ratio (at least 50 wt.% LDPEt and up to 50 wt.% LDPEa) to create a PE blend layer that exhibits synergistic properties. This composite polymer structure provides both the necessary flexibility for creasing and the strength to prevent tearing and leaking, resolving the contradiction between reliability and strength.
3Productivity
If standard polymer blends are used, then the production process can proceed at normal speed, but higher reject rates occur due to tearing and functional malfunctions
Solution Approach 1:
The patent changes the material parameters by specifying a damping factor difference between -0.3 and -0.6 for the PE blend layer, and controlling the molecular characteristics of LDPEa and LDPEt. These parameter adjustments optimize the material's viscoelastic properties to prevent tearing in creasing regions while maintaining leakproofness.
Solution Approach 2:
The patent applies composite materials by combining LDPEa and LDPEt in a specific blend ratio (at least 50 wt.% LDPEt and up to 50 wt.% LDPEa) to create a PE blend layer that exhibits synergistic properties. This composite polymer structure provides both the necessary flexibility for creasing and the strength to prevent tearing and leaking, resolving the contradiction between reliability and strength.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates generally to a planar composite comprising as a layer sequence: i. a first PE blend layer; ii. a carrier layer; iii. a barrier layer; iv. a further PE blend layer; wherein the first PE blend layer or the further PE blend layer in each case comprises in a range of from 10 to 50 wt.%, in each case based on the blend, a first LDPEa; a further LDPEt to the extent of at least 50 wt.%, in each case based on the blend. The present invention furthermore relates to a process for the production of the planar composite, a container which surrounds an interior and comprises at least one such planar composite, and a process for the production of this container which comprises the steps of provision of the planar composite of the above mentioned layer construction, folding, joining and optionally filling and closing of the container obtained in this way.