Epoxy Resin Coating for Gas Barrier Laminate Adhesion
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Solution Overview
Problem
Existing epoxy resin compositions used in gas barrier films and laminates face issues with interlayer adhesiveness, particularly when using amine-based epoxy resin curing agents, leading to unstable adhesion to inorganic substances, and when used as a coating, they suffer from poor appearance and reduced gas barrier properties due to the addition of lubricants.
Innovation Solution
An epoxy resin composition containing an epoxy resin, an epoxy resin curing agent with an amine-based curing agent, and a polyalkylene glycol, optionally with an unsaturated fatty acid amide, to enhance adhesiveness, gas barrier properties, and coating appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PVDC layer is formed as a gas barrier layer, then good barrier properties and transparency are achieved, but hazardous acid gases are generated during incineration causing environmental problems
Solution Approach 1:
The patent replaces the PVDC layer with a PVA layer that can be designed to decompose harmlessly under controlled conditions. The PVA layer serves as a temporary protective barrier that fulfills its gas barrier function during use but can be safely disposed of after use, eliminating the persistent environmental harm caused by PVDC incineration.
Solution Approach 2:
The patent changes the chemical composition parameter from PVDC to PVA, fundamentally altering the material's decomposition behavior. This parameter change transforms the harmful incineration process into a safe decomposition process while maintaining the essential gas barrier properties during the product's service life.
2Reliability
If a PVA layer is formed to achieve excellent gas barrier properties under low humidity, then good barrier performance is obtained, but the gas barrier properties rapidly decrease at relative humidity of approximately 70% or higher due to high hygroscopicity
Solution Approach 1:
The patent creates a composite structure by laminating the PVA layer with other materials that have complementary properties. This composite approach allows the PVA layer to provide excellent gas barrier properties under low humidity while the combined structure maintains stable performance even at high humidity levels, compensating for PVA's hygroscopic limitations.
3Reliability
If an inorganic vapor-deposited film is used to achieve good gas barrier properties and transparency, then excellent barrier performance is obtained, but cracks are generated in the vapor-deposited inorganic layer during bending causing significant reduction of gas barrier properties
Solution Approach 1:
The patent replaces the rigid inorganic vapor-deposited film with a flexible PVA-based organic film. This flexible film can accommodate bending deformations without cracking, maintaining the integrity of the gas barrier layer while providing the necessary flexibility for practical applications.
4Strength
If an epoxy resin composition containing an amine-based curing agent is used to improve bending resistance, then bending resistance is enhanced, but interlayer adhesiveness becomes unstable particularly to inorganic substances
Solution Approach 1:
The patent introduces a silane coupling agent as a localized component within the epoxy resin composition. This coupling agent specifically targets the interface between the epoxy resin and inorganic substances, providing localized adhesion enhancement at the critical bonding interface while the bulk epoxy resin maintains its bending resistance properties.
Solution Approach 2:
The silane coupling agent acts as an intermediary substance that bridges the epoxy resin and inorganic substances. It provides chemical bonding groups that interact with both the epoxy resin matrix and the inorganic surface, creating a stable adhesive interface that overcomes the instability caused by using amine-based curing agents alone.
5Shape
If lubricants are added to epoxy resin composition to improve coating appearance, then coating appearance is enhanced, but gas barrier properties are reduced
Solution Approach 1:
The patent uses a silane coupling agent as an intermediary that allows the use of minimal lubricant amounts. The coupling agent improves the interfacial adhesion between the epoxy resin and substrate, enabling the system to maintain good coating appearance with reduced lubricant content, thereby preserving the gas barrier properties that would otherwise be compromised by higher lubricant concentrations.
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 composition forms a curing coating film with high gas barrier properties, sufficient adhesiveness, and a good appearance, suitable for various packaging materials.
Implementation Method 1
an epoxy resin composition containing an epoxy resin, an epoxy resin curing agent containing an amine-based curing agent, and a polyalkylene glycol
Implementation Method 2
the composition forms a curing coating film with high gas barrier properties
Data Source
AI summary
An epoxy resin composition containing an epoxy resin, an epoxy resin curing agent containing an amine-based curing agent, and a polyalkylene glycol, as well as a gas barrier laminate and a packaging material in which the epoxy resin composition is used.