Thermally Activatable Laminating Material for Flexible Packaging
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Solution Overview
Problem
Current methods for producing flexible packaging materials require a prolonged curing time for solvent-based or solvent-free laminating adhesives, leading to a lag between production and readiness for packaging, which is inefficient.
Innovation Solution
A process involving a first flexible substrate with an ink composition printed on it and a second flexible substrate with a thermally activatable laminating material, where the laminating material is a copolymer of alkylene monomers and acrylic or methacrylic acids, allowing immediate lamination and bonding without the need for curing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solvent-based or solvent-free laminating adhesives are used, then bond strength is achieved, but prolonged curing time is required
Solution Approach 1:
The patent changes the chemical composition parameters of the laminating material by using a copolymer of alkylene monomers and acrylic or methacrylic acids, which fundamentally alters the bonding mechanism to eliminate the need for prolonged curing time while maintaining bond strength
Solution Approach 2:
The thermally activatable laminating material undergoes a phase transition when heated, changing from an inactive state to an active bonding state. This thermal activation allows immediate bonding without requiring prolonged curing time, as the phase change triggers rapid adhesion between layers
2Strength
If prolonged curing time is required, then adequate bond strength is achieved, but production efficiency decreases
Solution Approach 1:
The laminating material is prepared in advance with thermally activatable properties, so that when heating is applied during the lamination process, bonding occurs immediately without requiring prolonged curing time. This preliminary preparation of the material enables instant activation and bonding, eliminating production delays
Solution Approach 2:
By changing the material parameters to use a copolymer with specific acrylic or methacrylic acid content, the bonding process transitions from a slow curing mechanism to a rapid thermal activation mechanism, achieving both adequate bond strength and high production efficiency
3Loss of time
If thermally activatable laminating material is used, then immediate bonding is achieved, but specific material composition requirements are imposed
Solution Approach 1:
The patent uses a composite material approach by creating a copolymer of alkylene monomers and acrylic or methacrylic acids. This composite structure combines the benefits of different monomers to achieve thermally activatable properties while maintaining workability and eliminating the need for complex curing processes
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 immediate lamination and bonding, streamlining the production process and eliminating the need for curing time, resulting in a flexible packaging material with sufficient bond strength to prevent delamination.
Implementation Method 1
a layer of thermally activatable laminating material... contacting under conditions of heat and/or pressure the layer of thermally activatable laminating material with the other of the second flexible substrate and the first surface of the first flexible substrate
Data Source
AI summary
A process for preparing a flexible packaging material (5) is described. The process comprising providing a first flexible substrate (3) having a first surface on which an ink composition (4) is printed, the printed ink composition comprising an ink resin comprising polyvinyl chloride, polyvinyl butyral, nitrocellulose, polyurethane, polyamide or a UV curable resin; providing a second flexible substrate (1); depositing a layer of thermally activatable laminating material (2) onto one of a first surface of the second flexible substrate and the first surface of the first flexible substrate on which the ink composition is printed, the thermally activatable laminating material comprising a thermally activatable polymer selected from a copolymer of an alkylene monomer and an acrylic acid or methacrylic acid monomer, a copolymer of an alkylene monomer and an alkyl acrylate or alkyl methacrylate monomer, a polyurethane, an ionomer, a copolymer of alkylene monomers, a maleic anhydride modified polyalkylene and an acid modified polyolefin; and contacting under conditions of heat and/or pressure the layer of thermally activatable laminating material with the other of the second flexible substrate and the first surface of the first flexible substrate on which the ink composition is printed.