Multi-layer films using renewable polymers
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Solution Overview
Problem
Current multi-layer films used in disposable products are primarily derived from non-renewable petroleum resources, leading to high costs and environmental concerns, as well as consumer aversion to petrochemical-based products.
Innovation Solution
Development of multi-layer films comprising polymers derived from renewable resources, specifically using low density polyethylene (LDPE) and linear low density polyethylene (LLDPE) with a copolymer and homo polypropylene, where at least one of the polymers is synthetic and partially derived from renewable sources, reducing petroleum dependence and lowering costs while maintaining performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-layer films are made from petroleum-derived polymers, then manufacturing cost is reduced and performance characteristics are maintained, but environmental friendliness deteriorates and consumer acceptance decreases
Solution Approach 1:
The patent changes the source parameter of the polymer material from petroleum-based to renewable resource-based (such as bio-based polyethylene and polypropylene). This substitution maintains the chemical structure and performance characteristics of the polymers while fundamentally altering their environmental impact profile, allowing the film to achieve both cost-effectiveness and environmental friendliness
Solution Approach 2:
The patent employs multi-layer composite film structures combining different polymers (polyethylene and polypropylene in various ratios) where at least one layer contains renewable resource-derived polymer. This composite approach allows optimization of both mechanical properties and bio-based content, achieving a balance between performance requirements and environmental sustainability
2Strength
If multi-layer films use higher basis weight, then performance characteristics are improved, but petroleum usage increases and cost increases
Solution Approach 1:
The patent changes the basis weight parameter of the film to lower ranges (e.g., 5-20 microns for certain layers) while compensating for strength requirements through optimized polymer selection and multi-layer configuration. This reduces the total quantity of petroleum-derived material needed while maintaining adequate performance through the strategic use of renewable resource polymers
3Quantity of substance
If multi-layer films are made thinner (lower basis weight), then petroleum usage is reduced and cost is lowered, but performance characteristics may deteriorate
Solution Approach 1:
The patent uses multi-layer composite structures where thinner individual layers are combined to achieve the required overall performance. Each layer can be optimized for specific functions (barrier, structural, sealability) and the combination provides synergistic effects that maintain or enhance overall film performance despite reduced individual layer thickness and reduced petroleum content
Solution Approach 2:
The patent applies different polymer compositions and thicknesses to different layers based on their specific functional requirements. Critical areas requiring higher strength or barrier properties receive enhanced local composition (e.g., specific polymer types or higher thickness in seal layers or barrier layers), while other areas use thinner or less resource-intensive materials, optimizing the balance between performance and petroleum usage
Data Source
AI summary
A multi-layer film having a first film layer being at least partially formed from a polymer (A) and a polymer (B) and a second film layer being at least partially formed from the polymer (A), the polymer (B), a polymer (C), and optionally an opacifying agent, wherein at least one of the polymer (A), the polymer (B) and the polymer (C) is synthetic and is at least partially derived from a renewable resource such that the multi-layer film has a bio-based content of about 10% to about 100% using ASTM D6866-10, method B. Methods of forming multi-layer films are also provided.