Polymeric Adhesive Extrusion for Tabstock Laminate Bonding
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Solution Overview
Problem
Existing methods for producing laminate container closure systems with integrated tabs are inefficient, costly, and often result in residue issues or difficulties in removal, particularly with the use of wax-based adhesives and expensive materials like foam, which can lead to contamination and manufacturing complexities.
Innovation Solution
A method involving simultaneous unwinding of laminate feeds to a lamination station with rollers, where a polymeric adhesive is extruded between the tabstock and seal laminate layers to form a strong bond, allowing for efficient production of a primary laminate with a tabstock that can be easily attached to a secondary seal, using materials like polyethylene terephthalate and polypropylene, and applying a polymeric adhesive with specific properties to ensure strong bonding and print visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wax-based adhesive is used to attach primary seal to secondary liner, then bonding is achieved, but residue remains on container surface causing contamination
Solution Approach 1:
The patent changes the chemical composition parameter of the adhesive from wax-based to plastics-based material. This parameter change eliminates the residue problem while maintaining bonding strength, as plastics-based adhesives do not leave harmful residues on container surfaces unlike wax-based adhesives
Solution Approach 2:
The patent uses a disposable release layer made of plastics-based adhesive that can be easily removed without residue. This release layer is applied only where needed and discarded after use, avoiding the contamination issue associated with persistent wax residues
2Ease of operation
If tab is formed by adhering top layer to remainder of seal across part of diameter, then removal facilitation is achieved, but production time increases and manufacturing complexity increases
Solution Approach 1:
The patent applies adhesive to the tabstock before lamination, so the bonding surfaces are pre-prepared. This preliminary action eliminates the need for time-consuming strip-by-strip adhesive application during production, while still achieving the desired tab functionality
Solution Approach 2:
The patent combines the adhesive application step with the lamination process itself. By applying adhesive continuously during the lamination operation rather than separately, the manufacturing process is merged into a single continuous operation, reducing production time
3Adaptability or versatility
If foam is used as primary seal material, then seal flexibility is improved, but cost increases and manufacturing complexity increases
Solution Approach 1:
The patent replaces expensive foam with a simpler, more cost-effective laminate structure consisting of multiple thin layers. This laminate achieves sufficient flexibility without requiring costly foam materials, reducing both material cost and manufacturing complexity
4Strength
If adhesive is applied in strips gradually, then bonding is achieved, but production efficiency decreases
Solution Approach 1:
The patent applies adhesive continuously across the entire bonding surface during the lamination process, rather than applying it in discrete strips. This continuous application method maintains constant bonding strength while significantly improving production efficiency by eliminating the strip-by-strip construction time
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 method enables a cost-effective, efficient production of a primary laminate with a tabstock that can be easily removed from containers without residue, ensuring strong bonding and maintaining container closure integrity while allowing for printing and visibility of manufacturer information.
Implementation Method 1
a polymeric adhesive is extruded between the tabstock and seal laminate layers to form a strong bond
Implementation Method 2
a polymeric adhesive is extruded between the tabstock and seal laminate layers
Data Source
AI summary
A method for producing a primary laminate including a tabstock by feeding a seal laminate comprising bottom food contact layers including a foil layer and a top polyester layer to a laminating station wherein either the foil layer of the underside of the polyester layer has been printed; simultaneously feeding a tabstock, which is narrower than the seal laminate, to the laminating station such that the bottom of the tabstock and the top polyester layer of the seal laminate come into contact to form a primary substrate, simultaneously feeding a plastic film stock; and continuously extruding a polymeric adhesive between the top face of the primary substrate and bottom surface of the plastic film stock.