Recyclable Bulk Container Liners with Polypropylene Outer Ply
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Solution Overview
Problem
Existing bulk container liners face challenges in providing both abuse resistance and recyclability while minimizing the use of metals and nylons, which are costly and complex to recycle.
Innovation Solution
The use of a multi-layered outer ply comprising polypropylene-based film layers, with specific configurations of polypropylene and polyethylene layers, and a polyethylene-based inner ply, achieving a high polyolefin content of 90% or greater, allowing for recyclability without compromising performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal-containing polymer films or nylon films are used for oxygen barrier purposes, then oxygen barrier protection is improved, but recycling complexity and cost increase
Solution Approach 1:
The patent removes metal-containing layers and nylon layers from the liner structure, extracting the problematic materials that cause recycling complexity while maintaining the necessary barrier and mechanical properties through alternative polyolefin-based materials
Solution Approach 2:
The patent changes the material composition parameters by using polypropylene-based film layers with specific weight percentages (10-50%) combined with polyethylene-based layers, achieving both barrier protection and recyclability through optimized material parameters
2Device complexity
If polypropylene-based film layers are used to replace metals or nylons, then recyclability is improved, but flex crack resistance and puncture resistance may be compromised
Solution Approach 1:
The patent creates a composite structure combining polypropylene-based film layers with polyethylene-based film layers, where the polypropylene provides puncture resistance and the polyethylene provides flex crack resistance, achieving both strength properties and recyclability simultaneously
Solution Approach 2:
The patent applies different polymer materials to different functional requirements within the same liner structure, using polypropylene specifically for puncture resistance and polyethylene specifically for flex crack resistance, optimizing each material's contribution to the overall performance
3Strength
If multi-layered outer ply configuration is used, then flex crack resistance and puncture resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the outer ply into multiple discrete layers with specific functions, where each layer contributes to different aspects of mechanical protection, allowing the complexity to be managed through modular layer design rather than monolithic construction
Data Source
AI summary
Described are liners for bulk containers such as intermediate bulk containers (IBC) that are abuse-resistant and barrier-providing. The liners are recyclable. The liners have at least one sidewall that is multi-plied and the plies are multi-layered. The liners are preferably metal-free and nylon-free. An outer ply comprises at least one discrete polypropylene-based film layer. Addition of polypropylene α-olefin to sealant and/or polypropylene-based film layers also improves performance. Methods of making and using the liners are also provided.