Trilaminate Process Variable Density Polymer Multilaminate
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Solution Overview
Problem
Existing multilaminate processes face challenges in producing uniform, hermetic packages without manual seams, leading to non-uniform finishes and reduced efficiency, as well as issues with liquid retention and resistance to external forces.
Innovation Solution
A trilaminate process using a formulated polymeric adhesive, combining low or ultra-low density homopolymer materials with copolymers, catalyzed by ultrasound and temperature, to create a multilaminate product with variable density and enhanced properties such as resistance, flexibility, and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multilaminate processes are used, then production can be achieved, but manual seams result in non-uniform finishes and reduced manufacturing precision
Solution Approach 1:
The patent replaces manual mechanical sealing operations with an automated ultrasonic welding system. The ultrasonic welding apparatus applies controlled mechanical vibration and heat to fuse polymeric layers automatically, eliminating manual seams and achieving uniform finishes across the entire multilaminate surface without human intervention.
Solution Approach 2:
The patent employs controlled changes in temperature and pressure parameters during the sealing process. By adjusting thermal parameters through ultrasonic heating and controlling pressure during lamination, the process achieves uniform bonding across different polymeric layers while maintaining automated operation, resolving the contradiction between precision and automation.
2Reliability
If conventional sealing methods are used, then packaging can be produced, but liquid retention and resistance to external forces are insufficient
Solution Approach 1:
The patent creates a composite multilaminate structure combining different polymeric materials with complementary properties. The formulation includes polyethylene copolymers with varying densities and melting points, along with polypropylene and polyamide layers, creating a composite structure that simultaneously achieves liquid retention through hydrophobic properties and resistance to external forces through layered reinforcement.
Solution Approach 2:
The patent incorporates a foam layer within the multilaminate structure that provides beforehand cushioning against external forces. This foam layer acts as a buffer that absorbs and distributes mechanical stresses before they reach the sealing layers, enhancing overall resistance to external forces while maintaining liquid retention capabilities through the hydrophobic polymeric layers.
3Productivity
If existing multilaminate processes are used, then production can proceed, but manufacturing efficiency is reduced due to manual operations
Solution Approach 1:
The patent implements continuous automated ultrasonic welding that operates without interruption throughout the lamination process. The ultrasonic welding apparatus maintains continuous contact with the polymeric layers, providing uninterrupted sealing action that eliminates the start-stop nature of manual operations and maximizes manufacturing efficiency while minimizing time loss.
Solution Approach 2:
The ultrasonic welding system performs self-service by automatically detecting and adjusting sealing parameters based on real-time feedback from the lamination process. The system self-regulates temperature, pressure, and welding duration without manual intervention, optimizing productivity while eliminating time-consuming manual adjustments and enhancing overall manufacturing efficiency.
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 fully automated production of multilaminate products with improved resistance to forces over 100 kg/cm², flexibility, and thermal insulation, while preventing cracks and ensuring liquid retention, thus enhancing the manufacturing efficiency and versatility of various products like bags, coveralls, and packaging.
Implementation Method 1
a formulated polymeric adhesive that bonds different polymer layers together
Implementation Method 2
catalyzed by ultrasound and temperature
Implementation Method 3
catalyzed by ultrasound and temperature
Data Source
AI summary
A process for making a multilaminate containing polymers of variable density is provided. The method involves making a bilayer roll 1 by laminating a layer containing a formulated polymer adhesive (component (2)) and a layer containing a non-woven fabric containing at least 50% recycled polypropylene resin (component (3)); making a trilayer roll 2 containing three laminated layers by laminating a layer containing a bioriented polypropylene (component (1)) and a bilayer from roll 1; making a trilayer roll 3 containing three laminated layers by laminating a layer containing a polyethylene foam having uniformly distributed air bubbles (component (4)) and a bilayer from roll 1; and making a multilayer roll 4 and a multilayer roll 5, each containing at least two selected from a bilayer from roll 1, a trilayer from roll 2, and a trilayer from roll 3. The multilaminate may contain five or more layers.