Barrier Laminate Coating for Gas Barrier and Interlayer Adhesion

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Solution Overview

Problem

Existing polyester film substitutes, such as stretched polypropylene films, suffer from interlayer separation and inadequate gas barrier properties when an evaporated film is applied, leading to impaired performance in packaging containers.

Innovation Solution

A multilayer substrate comprising a polypropylene resin layer subjected to stretching and a surface coating layer with a polar group, combined with an evaporated film of inorganic oxide, enhances adhesiveness and gas barrier properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a stretched polypropylene film is used as a substitute for polyester film, then cost and availability are improved, but gas barrier properties and interlayer adhesiveness deteriorate

Engineering Contradiction:

Improveavailability of substrateVSAvoidgas barrier properties

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies composite materials by combining stretched polypropylene film with a surface coating layer containing polar groups (such as hydroxyl groups). This composite structure resolves the contradiction by maintaining the cost advantages of polypropylene while adding the gas barrier properties and adhesiveness characteristics through the coating layer, achieving both economic feasibility and functional performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies parameter changes by modifying the surface properties of the stretched polypropylene film through coating with materials containing polar groups. This changes the surface energy and chemical composition parameters, enabling the film to achieve adequate gas barrier properties and interlayer adhesiveness that the base polypropylene material alone cannot provide.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If an evaporated film is formed on stretched polypropylene film, then gas barrier properties are improved, but interlayer separation occurs leading to impaired gas barrier properties

Engineering Contradiction:

Improvegas barrier propertiesVSAvoidinterlayer adhesiveness

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by forming a surface coating layer containing polar groups on the stretched polypropylene film before depositing the evaporated film. This preliminary coating layer creates a surface that promotes strong adhesion between the substrate and the evaporated film, preventing interlayer separation and maintaining stable gas barrier properties throughout the laminate structure.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If polyester film is used as substrate, then gas barrier properties and interlayer adhesiveness are improved, but cost and availability are worsened

Engineering Contradiction:

Improvegas barrier propertiesVSAvoidcost of substrate

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by concentrating the gas barrier functionality and polar groups specifically in the surface coating layer, while the base polypropylene film provides the economic and structural foundation. This localized approach allows the expensive functional properties to be present only where needed (at the surface interface), rather than requiring the entire substrate to be made of expensive polyester film.

Inventive Principle:

Principle #3Local quality

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 solution results in a packaging container with high interlayer adhesiveness and laminate strength, providing superior gas barrier properties and improved durability.

Implementation Method 1

a surface coating layer containing a resin material with a polar group, wherein an evaporated film comprising an inorganic oxide is formed on the surface coating layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the evaporated film comprises an inorganic oxide

Methodology Applied

Scientific EffectPermeation barrier: Permeation

Data Source

PatentUS12497688B2Barrier laminate, heat sealing laminate including barrier laminate, and packaging container with heat sealing laminate

Publication Date: 2025.12.16 DAI NIPPON PRINTING CO LTD

AI summary

[Object] To provide a barrier laminate that includes a multilayer substrate with high interlayer adhesiveness to an evaporated film and that has high gas barrier properties.[Solution] A barrier laminate according to the present invention includes a multilayer substrate and an evaporated film, wherein the multilayer substrate includes at least a polypropylene resin layer and a surface coating layer, the polypropylene resin layer is subjected to a stretching process, the surface coating layer contains a resin material with a polar group, and the evaporated film is composed of an inorganic oxide.