Multi-ply Puckered Thermoplastic Films
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Solution Overview
Problem
Thermoplastic films produced with reduced thickness to lower costs often exhibit undesirable properties such as increased transparency and reduced physical strength, leading to consumer perception of decreased value.
Innovation Solution
Creating multi-ply, puckered thermoplastic films through cold formation stretching and non-continuous lamination of films with differing rebound ratios, resulting in increased loft and perceived strength without significant material increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thermoplastic films are made thinner to reduce material cost, then production cost decreases, but physical strength and perceived value deteriorate
Solution Approach 1:
The patent transitions from a single flat film structure to a multi-ply puckered structure by adding dimensional complexity. Multiple film plies are laminated together and then puckered to create a three-dimensional structure with increased loft, transforming the film from a two-dimensional flat surface to a three-dimensional textured structure that appears thicker and stronger while using less material
Solution Approach 2:
The patent uses composite construction by laminating multiple thermoplastic film plies together with different rebound ratios. These composite multi-ply structures are then puckered to create regions of varying thickness and density, combining multiple materials layers to achieve superior perceived strength and loft compared to single-layer films of equivalent material weight
2Area of stationary object
If thermoplastic films are stretched to increase surface area, then surface area increases and material usage decreases, but transparency increases and physical properties deteriorate
Solution Approach 1:
The patent divides the film structure into multiple discrete plies that are laminated together. Each ply can be independently stretched and processed, then combined into a multi-ply structure. This segmentation allows the film to achieve increased surface area through stretching while maintaining physical properties through the multi-ply construction and puckering process
3Shape
If multi-ply films with different rebound ratios are non-continuously laminated and released, then loft increases and perceived value improves, but manufacturing complexity increases
Solution Approach 1:
The patent exploits changes in the rebound ratio parameter of different thermoplastic film plies to create the desired puckered structure. By selecting films with different rebound ratios and laminating them in sequence, the natural elastic recovery differences cause automatic puckering upon release, transforming a complex structural formation process into a parameter-based material selection and lamination process
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 method enhances the physical properties and perceived value of thinner thermoplastic films by increasing loft and opacity, making them appear stronger and more valuable to consumers while reducing material usage.
Implementation Method 1
cold formation stretching one or more film plies
Implementation Method 2
non-continuously laminating two or more film plies together
Implementation Method 3
differences in the rebound ratio of the film plies can cause one or more of the plies to pucker between lamination points
Data Source
AI summary
Methods of increasing the loft of a multi-ply thermoplastic film include stretching thermoplastic films with different rebound ratios, non-continuously laminating the films together, and releasing the films to create puckers in one or more of the films. The puckers can comprise billowing of one of the films. The non-continuous laminated areas can maintain the puckers in the films. The puckers can increase the loft of the film, improve the feel of the film, and/or modify the look of the film. The loft of such multi-ply puckered thermoplastics films vary independent of the basis weight of the films. Thus, multi-ply puckered thermoplastics films with increased loft of one or more implementations can look and feel thicker while using reduced amounts of thermoplastic material.