Antibacterial Laminate with Poreless Polymer Coating
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Solution Overview
Problem
Existing food packaging materials with antibacterial properties face challenges such as direct contact of antibacterial agents with food, degradation due to exposure, and aesthetic issues like color changes, making them unsuitable for long-term food preservation.
Innovation Solution
A laminate structure is designed with a coating layer that prevents direct contact of antibacterial agents with air, using a silver vapor deposition layer with specific thickness and a poreless polymer coating to ensure sustained release and stability, while maintaining antibacterial and antifungal properties without exposing the agents to the outside.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic antibacterial agents are used and exposed on the surface, then antibacterial capability is achieved, but the antibacterial capability is degraded due to falling-off or oxidization and aesthetic feeling is degraded due to color changes
Solution Approach 1:
The patent embeds the antibacterial metal layer within a coating layer structure, where the coating layer acts as a protective shell enclosing the antibacterial metal. This nesting prevents direct exposure of the metal to air and food, thereby preventing oxidization and falling-off while maintaining antibacterial capability through controlled ion release.
Solution Approach 2:
The coating layer serves as an intermediary between the antibacterial metal layer and the external environment (food and air). It mediates the interaction by allowing controlled ion release from the metal while preventing direct contact between the metal and oxidizing agents, thus preserving both antibacterial capability and aesthetic appearance.
2Reliability
If organic antibacterial agents are used inside the package, then antibacterial property is achieved, but there is high possibility that the antibacterial agents directly contact with foods and there lies a concern for safety
Solution Approach 1:
The coating layer acts as an intermediary barrier between the antibacterial metal layer and the food. It allows the metal to exert antibacterial action through ion release while preventing direct contact between the metal and food, thereby maintaining safety. The coating layer mediates the interaction by controlling ion diffusion while blocking direct contact.
Solution Approach 2:
The coating layer is designed with controlled porosity to allow antibacterial metal ions to diffuse through to the food surface while preventing direct contact between the metal layer and food. The porous structure enables selective transport of ions while maintaining a physical barrier.
3Reliability
If a coating layer is added to protect antibacterial agents, then stability and safety are improved, but the structure becomes more complex
Solution Approach 1:
The patent optimizes the thickness of the coating layer and metal layer as key parameters to achieve the desired balance between protection and functionality. By carefully controlling these dimensional parameters, the structure achieves stable antibacterial performance with minimal complexity.
Solution Approach 2:
The patent creates a composite laminate structure combining the coating layer and antibacterial metal layer. This composite material approach integrates multiple functions (protection, ion release, aesthetic appearance) into a single integrated structure, reducing overall system complexity while improving reliability.
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 laminate achieves stable antibacterial and antifungal functions over time, prevents color changes, and provides a gas barrier property, ensuring food safety and quality without compromising aesthetics.
Implementation Method 1
a silver vapor deposition layer with specific thickness
Implementation Method 2
maintaining antibacterial and antifungal properties without exposing the agents to the outside
Implementation Method 3
prevents color changes
Implementation Method 4
provides a gas barrier property
Data Source
Figure 1~2
AI summary
In an antibacterial laminate that has at least either of an antibacterial property and an antifungal property, the antibacterial laminate of the present invention is at least constituted of a substrate layer 4 which includes a polymer film or paper, an antibacterial layer 2 which is a vapor deposited metal that has at least either of an antibacterial property and antifungal property, and a coating layer 1 for coating the antibacterial layer 2, wherein the antibacterial layer 2 is formed between the substrate layer 4 and the coating layer 1, and the coating layer 1 is substantially a poreless polymer coated film.