Colored Adhesive Laminate for Delamination-Resistant Packaging
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Solution Overview
Problem
The existing packaging materials for batteries, when colored with pigments like carbon black, face issues with adhesive force deterioration and delamination due to non-uniform pigment dispersion, leading to poor moldability and durability, especially under harsh environments.
Innovation Solution
A packaging material with a substrate layer made of heat-resistant resin, a metal foil layer, and a thermoplastic sealant layer, featuring a colored adhesive layer with a specific Young's modulus and pigment content, using a two-part curing type polyester urethane resin and a chemical conversion coating on the metal foil layer, along with a matte coat layer for improved moldability and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the amount of carbon black added to the adhesive layer is increased to make the adhesive layer black, then the colorability is improved, but the adhesive force deteriorates and delamination occurs
Solution Approach 1:
The patent optimizes the carbon black content parameter within a specific range (1-5 mass%) to achieve the desired black color while maintaining adhesive force. This parameter optimization resolves the contradiction by finding the optimal point where sufficient coloration is achieved without excessive pigment that would compromise adhesion.
Solution Approach 2:
The patent uses a composite adhesive system combining polyester resin and polyurethane resin in specific ratios, along with controlled carbon black dispersion. This composite approach allows the adhesive to maintain its bonding properties while achieving the desired color, as the resin matrix protects the adhesive interface from pigment aggregation.
2Illumination intensity
If the amount of carbon black added to the adhesive layer is increased to make the adhesive layer black, then the colorability is improved, but moldability deteriorates due to delamination
Solution Approach 1:
The patent specifies optimal carbon black content (1-5 mass%) and adhesive layer thickness (5-20 μm) parameters to ensure both colorability and moldability. By controlling these parameters, the adhesive layer achieves sufficient black coloration while maintaining the flexibility and adhesion needed for successful molding without delamination.
Solution Approach 2:
The patent applies a controlled amount of carbon black (not excessive amounts) to achieve the desired color effect while preserving the adhesive layer's functional properties. This partial action approach ensures enough pigment for coloration without over-saturating the adhesive, which would compromise moldability.
3Illumination intensity
If pigment is added to the adhesive layer to serve as identification label, then the colorability is improved, but the adhesive force deteriorates
Solution Approach 1:
The patent optimizes pigment concentration within a specific range (1-5 mass%) to achieve identification coloration while maintaining adhesive strength. This controlled parameter change ensures the adhesive layer remains sufficiently strong for bonding while displaying the required color for identification purposes.
Solution Approach 2:
The patent uses a carefully formulated adhesive matrix (polyester-polyurethane composite) as an intermediary that disperses pigment particles uniformly and protects the adhesive-pigment interface. This intermediary matrix allows coloration to occur without the pigment directly compromising the adhesive bonding mechanism.
4Illumination intensity
If pigment is added to the adhesive layer to serve as identification label, then the colorability is improved, but delamination occurs between substrate layer and adhesive layers during molding
Solution Approach 1:
The patent controls pigment content (1-5 mass%) and adhesive layer thickness (5-20 μm) to prevent delamination during molding. By optimizing these parameters, the adhesive layer maintains sufficient integrity and adhesion strength to withstand molding processes while displaying the required color for identification.
Solution Approach 2:
The patent employs a composite adhesive system (polyester resin + polyurethane resin) with controlled pigment dispersion that maintains delamination resistance. The composite structure provides both coloration capability and the mechanical integrity needed to prevent layer separation during molding and under harsh environmental conditions.
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 provides excellent moldability, colorability, and durability, preventing delamination and maintaining adhesive strength even under high-temperature and high-humidity conditions, ensuring the packaging material's integrity and appearance.
Implementation Method 1
a chemical conversion coating on the metal foil layer
Implementation Method 2
using a two-part curing type polyester urethane resin
Data Source
AI summary
A packaging material excellent in moldability, colorability, and strength is provided. The packaging material includes a substrate layer made of a heat-resistant resin, a metal foil layer laminated on an inner side of the substrate layer, a sealant layer made of a thermoplastic resin laminated on an inner side of the metal foil layer, and a colored adhesive layer provided between the metal foil layer and the substrate layer. The colored adhesive layer is formed of a colored adhesive cured film containing a color pigment and an adhesive. The colored adhesive cured film has a Young's modulus of 450 MPa to 700 MPa by a tensile test according to JIS K7161-1: 2014.