Antislip flexible materials and methods for their making and use
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Solution Overview
Problem
Existing flexible packaging materials are too slippery, leading to issues such as stacks of bagged goods losing shape or falling apart during transport, and workers slipping on wrapped items, especially in moist or icy conditions. Current antislip solutions are often sensitive to contaminants and compromise heat-shrinkability, manufacturing processes, and recycling capabilities.
Innovation Solution
A method involving discrete thermoplastic particles heated to a tacky state are applied to a thermoplastic flexible carrier to form an antislip coating with controlled roughening projections, allowing for independent optimization of antislip parameters without affecting the carrier's properties, using a process that avoids pre-heating the carrier and allows for efficient heat bonding with minimal heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-slippery substance (e.g., elastomeric) is applied to the surface to increase friction, then the coefficient of friction improves, but the solution becomes sensitive to contaminants such as fine dust, moisture, ice, or grease
Solution Approach 1:
The patent changes the fundamental mechanism from relying on material friction properties to relying on mechanical interlocking geometry. By transforming the surface into protruding structures (nubs, ridges, or embossments) with specific geometric parameters (height, spacing, shape), the antislip effect becomes independent of surface contamination, as the mechanical interlock operates through physical engagement rather than frictional contact
Solution Approach 2:
The patent replaces the chemical/tribological mechanism (friction based on material properties) with a purely mechanical mechanism (interlocking based on geometry). The protruding structures create physical engagement that prevents slippage through mechanical constraint rather than through frictional forces that are sensitive to surface conditions
2Ease of manufacture
If an elastomeric component is included in the extrusion for integrated antislip manufacturing, then antislip features are built-in, but it becomes difficult to simultaneously optimize antislip parameters and manufacturing parameters
Solution Approach 1:
The patent divides the manufacturing process into separate stages: first producing the base flexible material with its inherent properties optimized for manufacturing, then subsequently adding the antislip surface features through a separate coating or embossing process. This segmentation allows independent optimization of each function without compromise
Solution Approach 2:
The patent prepares the base material in advance with optimized manufacturing parameters, then applies the antislip features as a subsequent treatment. This preliminary preparation of the substrate enables the antislip properties to be added without interfering with the base material's manufacturing optimization
3Reliability
If heat-shrinkable packaging material is made antislip through roughening, then antislip performance improves, but heat-shrinkability and homogeneity are compromised
Solution Approach 1:
The patent applies antislip features only to the outer surface of the packaging material while leaving the bulk material properties unchanged. The protruding structures are confined to a thin surface layer, allowing the underlying homogeneous heat-shrinkable material to maintain its composition and shrinkage behavior intact
4Adaptability or versatility
If a ready-made web is converted to antislip products in a subsequent operation, then customer requests can be responded to quickly, but the antislip features may not provide sufficient wear resistance
Solution Approach 1:
The patent optimizes the geometric parameters of the protruding structures (increasing height, adjusting spacing, modifying shape) to enhance durability and wear resistance. By carefully selecting parameters such as nub height of at least 10 micrometres and appropriate spacing, the surface features become more resistant to wear while maintaining the flexibility of subsequent application
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 solution provides a flexible, contamination-resistant antislip coating that maintains the carrier's strength, flexibility, and heat-shrinkability, while being economical and suitable for various manufacturing speeds, enabling effective antislip performance on both porous and non-porous materials without compromising their properties.
Implementation Method 1
discrete thermoplastic particles heated to a tacky state
Implementation Method 2
sticking the first layer to the front surface
Implementation Method 3
utilising a heat energy of the hot coating forming a bond between the carrier and the coating
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A method for forming an antislip material. A flexible thermoplastic carrier (13) is provided. A hot release surface (45) is provided. Provided is a first layer (29) of discrete thermoplastic particles (39), sitting on the hot release surface (45). The discrete particles (39) are above their softening temperatures, providing in the first layer (29) a tackiness. The method includes contacting the carrier (13) with the tacky first layer for sticking the first layer (29) to the carrier (13), and thereafter removing the carrier, and therewith the tacky first layer stuck to the carrier, from the release surface (45). Thereby the carrier (13) is provided with a hot, preferably discontinuous and/or elastomeric antislip coating. With a heat energy of the hot coating a bond is formed between the carrier and the coating. The removing of the carrier (13) includes pulling the carrier out of the contact with a pulling-out force. The temperature of the hot release surface (45) is above the melting temperature of the carrier (13). The carrier would be spoiled, if heated completely to the temperature of the release surface and simultaneously pulled with the pulling-out force. Therefore the contacting time is kept shorter than a minimum time required by a heat of the hot release surface (45) for spoiling the carrier (13). Flat-topped roughening projections (31) can be included in the antislip coating.