Systems, apparatus, and methods for creating thin plastic films
AssigneeParagon Films, Inc.
InventorTom Roudebush
Life of this patent
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Abstract
A multi-layer plastic film is describe herein that comprises at least one first layer comprising a metallocene linear low density polyethylene (mLLDPE) octene resin, at least one second layer comprising a linear low density polyethylene (LLDPE) octene resin, at least one third layer comprising a polypropylene (PP) resin, wherein the at least one third layer comprises one of a metallocene homopolymer polypropylene (mHPP) resin, a random copolymer polypropylene (RCPP) resin, and a metallocene polypropylene (mPP) resin. The multi-layer plastic film comprises a thickness of six microns or less.
Claims25
A method comprising:
- providing a plurality of source materials for a coextrusion process, wherein the plurality of source materials comprises a metallocene linear low density polyethylene (mLLDPE) octene material, a linear low density polyethylene (LLDPE) octene material, and a polypropylene (PP) material, wherein at least one of the plurality of source materials comprises a recycled source material;
- filtering the at least one of the plurality of source materials comprising the recycled source material;
- coextruding the plurality of source materials from a single die to form a film with five layers;
- slitting the film into a plurality of sections;
- moving the plurality of sections through a folding mechanism, wherein the folding mechanism produces edge folds at edges of the plurality of sections, wherein the step of filtering is configured to prevent downstream passage of melt impurities and/or gels from the recycled source material from causing lost folds;
- oscillating the plurality of sections;
- passing the plurality of sections over a retractable roller that is parallel to a film roll and moves vertically away from the film roll at a separation rate that maintains a distance between the retractable roller and the film roll;
- and
- winding the plurality of sections onto the film roll.
A method comprising:
- providing a plurality of source materials for a coextrusion process, wherein the plurality of source materials comprises a metallocene linear low density polyethylene (mLLDPE) octene material, a linear low density polyethylene (LLDPE) octene material, and a polypropylene (PP) material, wherein at least one of the plurality of source materials comprises a recycled source material;
- filtering the at least one of the plurality of source materials comprising the recycled source material;
- coextruding the plurality of source materials into a multi-layer film having a first outer layer and a second outer layer each comprising the mLLDPE octene material, wherein the multi-layer film has a total thickness of six (6) microns or less;
- slitting the film into a first section and a second section;
- passing the first and second sections across a first roller;
- and
- moving the first and second sections directly from the first roller past a folding rod so that the folding rod folds an edge of the first section upon itself and creates a first edge fold with the first outer layer of the first section clinging to the second outer layer of the first section, wherein the step of filtering is configured to prevent downstream passage of melt impurities and/or gels from the recycled source material from causing lost folds.
Dependencies are inferred from the claim text.