Separable Resin Laminate for Clean Packaging and Recycling
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Solution Overview
Problem
Existing packaging solutions for clean environments, such as those used for semiconductor products, suffer from inefficiencies in packaging processes due to multiple deaeration steps and interlayer lifting issues, while also contributing to environmental concerns like plastic pollution.
Innovation Solution
A laminate with separable resin layers, where the separation strength is 1.0 N/15 mm width or less, and includes a polyethylene layer with a density of 0.909 g/cm3 or less, or a polyolefin-based sealant layer with 82% mass content, and optionally incorporates biomass-derived resin materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separable surface film is used to enable clean packaging bag entry into clean room, then cleanliness requirement is met, but interlayer lifting occurs and appearance is impaired
Solution Approach 1:
The patent changes the separation strength parameter to a specific range (0.03-0.8 N/15mm width) to prevent interlayer lifting while maintaining cleanability. This parameter optimization resolves the contradiction by ensuring the surface film remains attached during handling but can be separated for cleaning purposes.
Solution Approach 2:
The patent creates a dynamic separation system where the surface film can transition from a attached state (during packaging and handling) to a separable state (for cleaning). The controlled separation strength enables this dynamic behavior, allowing the film to remain intact during normal use but be easily removed for maintenance.
2Reliability
If double deaeration and packaging is performed to ensure cleanliness, then contamination is prevented, but work efficiency is reduced
Solution Approach 1:
The patent segments the packaging system into a separable surface film and a base film, allowing the surface film to be cleaned or replaced without affecting the base packaging structure. This segmentation enables single-packaging efficiency while maintaining cleanliness through selective film replacement rather than complete repackaging.
Solution Approach 2:
The patent enables the surface film to be discarded (separated and removed) and recovered (reused or replaced) independently from the base packaging. This allows the base packaging to be reused for multiple articles, improving work efficiency while maintaining cleanliness by replacing only the contaminable surface film.
3Reliability
If traditional packaging materials are used to ensure functionality, then packaging performance is maintained, but recyclability and environmental load are poor
Solution Approach 1:
The patent segments the packaging into separable film layers that can be independently processed for recycling. The surface film and base film can be separated and recycled through different streams, improving overall recyclability while maintaining packaging performance through the coordinated function of each layer.
Solution Approach 2:
The patent uses composite film structures with specific material compositions that balance packaging performance with recyclability. By selecting materials with appropriate separation characteristics and compatibility, the packaging maintains functionality while enabling more efficient recycling processes and reduced environmental impact.
Data Source
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Figure 6A~6B
AI summary
A laminate including at least a first resin layer and a second resin layer, wherein the first resin layer is provided so as to be separable from the second resin layer, and the separation strength between the first resin layer and the second resin layer is 1.0 N/15 mm width or less and satisfies the following requirements (1) and/or (2): (1) the second resin layer is a sealant layer including at least a polyethylene layer with a density of 0.909 g/cm3 or less, and the polyethylene layer in the second resin layer is in contact with the first resin layer, and/or (2) the second resin layer is a sealant layer containing a polyolefin as a main component and has a polyolefin content of 82% by mass or more based on a mass of the second resin layer.