Thin Plastic Film Coextrusion with Edge Folding
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Solution Overview
Problem
Existing methods for producing thin gauge plastic films are inefficient and often result in films with thicknesses greater than 8 microns, which can lead to increased material usage and sustainability issues, while also being prone to tears and ruptures due to contamination from recycled resins.
Innovation Solution
An in-line coextrusion process that incorporates continuous filtration and edge folding, allowing for the production of films with thicknesses of 6 microns or less, utilizing a combination of LLDPE Octene, Metallocene HPP, and Metallocene LLDPE Octene resins, with recycled resins being filtered and integrated to reduce contamination and enhance film strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing methods are used to produce thin gauge plastic films, then production efficiency is maintained, but film thickness cannot be reduced below 8 microns and material purity is compromised due to recycled resin contamination
Solution Approach 1:
The film production process is segmented into multiple coextrusion layers, with virgin resins forming outer layers and filtered recycled resins forming inner layers. This segmentation allows thin gauge production (6 microns or less) while maintaining structural integrity through the layered architecture, resolving the contradiction between thickness reduction and strength maintenance.
Solution Approach 2:
A continuous filtration system acts as an intermediary between recycled resin input and film formation. The filtration system removes contaminants from recycled resins before they are coextruded into the film structure, enabling the use of thin gauge films without catastrophic failures from contamination, thus resolving the contradiction between thickness reduction and reliability.
2Reliability
If virgin plastic is used exclusively to ensure film strength and purity, then film reliability is improved, but sustainability is reduced due to increased material usage
Solution Approach 1:
The system recovers and reuses recycled plastic resins that would otherwise be discarded or downcycled. Through continuous filtration and coextrusion with virgin resins, the system transforms low-value recycled materials into high-performance thin gauge films, reducing virgin plastic usage while maintaining film strength and preventing contamination-related failures.
Solution Approach 2:
The film is constructed as a composite material system combining virgin and recycled resins in specific layers. The virgin resins provide structural integrity and contamination resistance, while filtered recycled resins contribute to film formation and reduce virgin material consumption. This composite approach resolves the contradiction between reliability and sustainability.
3Loss of substance
If film thickness is reduced to 6 microns or less for sustainability, then material usage is reduced, but film strength and resistance to tears and ruptures deteriorate
Solution Approach 1:
The thin gauge film is segmented into multiple coextruded layers, each contributing specific functional properties. The layered structure with virgin and filtered recycled resins provides enhanced strength and tear resistance at 6 microns or less thickness, resolving the contradiction between material reduction and strength maintenance.
Solution Approach 2:
The system changes the compositional parameters of the film by incorporating filtered recycled resins with specific molecular weights and purity levels. This parameter optimization enables thin gauge films (6 microns or less) to achieve sufficient strength and tear resistance that would be impossible with conventional single-layer structures.
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 process enables the production of thin gauge films with improved sustainability by reducing virgin plastic usage, enhancing film strength through edge folding, and preventing catastrophic failures due to contamination, while maintaining film clarity and flexibility.
Implementation Method 1
filtering the plurality of molten resins
Implementation Method 2
coextruding the plurality of materials into a multi-layered film
Implementation Method 3
folding resulting edges
Data Source
AI summary
A multi-layer film comprising, an outer two layers of the multi-layer film comprising a linear low density polyethylene (LLDPE) butene resin, a next two inwardly successive layers of the multi-layer film comprising a linear low density polyethylene (LLDPE) hexene resin, wherein at least one of the next two inwardly successive layers comprises one or more recycled resin components, wherein at least one of the one or more recycled resin components are filtered using continuous filtration, a core layer of the multi-layer film comprising a linear low density polyethylene (LLDPE) hexene resin, and at least one edge of the multi-layer film comprising a folded edge.