Actinic-Curable Resin Composition for Gas Barrier Film Adhesion
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Solution Overview
Problem
The active energy ray-curable resin composition described in Patent Document 3 experiences a decrease in adhesion to vapor-deposited inorganic substance films over time, leading to reduced gas barrier properties in gas barrier films and laminates.
Innovation Solution
The composition includes a reaction product of meta-xylylenediamine or para-xylylenediamine with unsaturated carboxylic acids and derivatives, combined with a compound having glycidyl or isocyanate groups and a phosphoric acid derivative with ethylenically unsaturated bonds, which improves adhesion and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the active energy ray-curable resin from Patent Document 3 is used, then excellent gas barrier properties and transparency are achieved, but adhesion to vapor-deposited inorganic substance films decreases over time
Solution Approach 1:
The patent modifies the chemical composition parameters of the active energy ray-curable resin by incorporating specific compounds (isocyanate group-containing compound and phosphoric acid derivative) in controlled amounts. This chemical parameter adjustment enhances both the gas barrier properties and long-term adhesion stability to inorganic substance films, resolving the contradiction between initial performance and temporal stability.
Solution Approach 2:
The patent creates a composite resin system by combining the base active energy ray-curable resin with specific functional compounds (isocyanate group-containing compound and phosphoric acid derivative). This composite formulation synergistically improves both gas barrier performance and adhesion stability, allowing the material to maintain excellent properties over time.
2Reliability
If inorganic substance vapor deposition is used to form gas barrier layer, then good gas barrier properties and transparency are achieved, but cracking occurs when bent reducing gas barrier properties
Solution Approach 1:
The patent employs a flexible resin composition that forms an adhesive layer between the inorganic vapor-deposited film and the substrate. This flexible film structure prevents cracking of the brittle inorganic layer during bending while maintaining the gas barrier properties, effectively resolving the contradiction between barrier performance and mechanical flexibility.
Solution Approach 2:
The patent introduces an intermediary resin layer that acts as a buffer between the rigid inorganic vapor-deposited film and the substrate. This intermediary layer absorbs mechanical stress during bending, preventing crack propagation in the inorganic film while preserving its gas barrier functionality.
3Reliability
If PVDC layer is formed as gas barrier layer, then transparency and good barrier properties are achieved, but hazardous gases are generated during incineration
Solution Approach 1:
The patent changes the material composition parameters by replacing PVDC with an inorganic vapor-deposited film (such as silica or alumina) combined with an organic-free or low-organic resin system. This compositional parameter change maintains excellent gas barrier properties and transparency while eliminating the generation of hazardous acids during incineration, resolving the environmental contradiction.
4Reliability
If PVA layer is formed as gas barrier layer, then excellent gas barrier properties under low humidity are achieved, but gas barrier properties rapidly decrease at high humidity
Solution Approach 1:
The patent changes the material parameters by substituting hygroscopic PVA with inorganic vapor-deposited films (silica, alumina) that have inherently low hygroscopicity. This parameter change maintains excellent gas barrier properties across all humidity conditions, resolving the contradiction between barrier performance and humidity stability.
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 modified composition maintains excellent gas barrier properties and adhesion to inorganic thin film layers, even when used after a lapse of time from preparation, enhancing the performance of gas barrier films and laminates.
Implementation Method 1
a phosphoric acid derivative having an ethylenically unsaturated bond-containing group
Data Source
Figure 1~2
AI summary
An active energy ray-curable resin composition containing: a reaction product (X) of a component (A) and a component (B) below: (A) at least one selected from the group consisting of meta-xylylenediamine and para-xylylenediamine; (B) at least one selected from the group consisting of unsaturated carboxylic acids represented by the following general formula (1) and derivatives of the unsaturated carboxylic acids: wherein, in the formula (1), R1 and R2 each independently represent a hydrogen atom, an alkyl group having from 1 to 8 carbon atoms, an aryl group having from 6 to 12 carbon atoms, or an aralkyl group having from 7 to 13 carbon atoms; (C) a compound having at least one group selected from the group consisting of a glycidyl group and an isocyanate group, and an ethylenically unsaturated bond-containing group; and (D) a phosphoric acid derivative having an ethylenically unsaturated bond-containing group.