Flexible Multilayer Packaging Film Oxygen Barrier
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Solution Overview
Problem
Current flexible high-barrier multilayer packaging films face challenges in maintaining ultra-high oxygen transmission rates, especially after flexing, and often require metal layers that are costly, opaque, and undesirable for recycling, while existing solutions like ceramic layers are sensitive to mechanical stress and lose barrier properties upon flexing.
Innovation Solution
A flexible multilayer packaging film with organic and inorganic layers, specifically polyvinyl alcohol and silicon oxide or aluminum oxide, applied via electron beam vacuum deposition, sandwiched between support and sealant layers, maintaining low oxygen transmission rates even after mechanical constraints, and using reduced or no metal layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrated aluminium layer is used to obtain high barrier properties, then oxygen transmission barrier is improved, but cost increases, opacity increases, and recyclability deteriorates
Solution Approach 1:
The patent removes the aluminium layer from the packaging film structure entirely, replacing it with an aluminium-free multilayer configuration consisting of polyolefin, polyamide, and polyvinylidene chloride layers. This extraction eliminates the harmful effects of metal layers (cost, opacity, recyclability issues) while maintaining the oxygen barrier function through the alternative polymer layer structure.
Solution Approach 2:
The patent employs a composite multilayer structure combining different polymer materials (polyolefin, polyamide, polyvinylidene chloride) to achieve the oxygen barrier properties previously provided by aluminium. Each layer contributes specific properties, and their combination creates a synergistic effect that matches or exceeds the barrier performance of metal layers without the associated drawbacks.
2Quantity of substance
If a thin aluminium foil is used to reduce metal content, then cost and weight are reduced, but pinholes form after flexing and barrier properties deteriorate
Solution Approach 1:
The patent replaces thin aluminium foil with a composite polymer structure where multiple layers work together to provide the barrier function. The polyamide and polyvinylidene chloride layers specifically contribute to oxygen barrier properties, while the polyolefin layer provides structural integrity and flexibility resistance, preventing pinhole formation during flexing.
Solution Approach 2:
The patent uses flexible polymer layers instead of rigid metal foils. The polyolefin and polyamide layers are designed with appropriate thicknesses and mechanical properties to provide flexibility and resistance to flexing, preventing the formation of pinholes that would compromise the barrier properties during normal packaging use.
3Reliability
If a very thick ceramic layer is applied to achieve high barrier properties, then oxygen transmission is reduced, but mechanical stress sensitivity increases and barrier properties are lost after flexing
Solution Approach 1:
The patent replaces the thick ceramic layer with a composite polymer structure where the polyamide and polyvinylidene chloride layers provide oxygen barrier properties. These polymer layers maintain flexibility and mechanical strength, allowing the film to withstand flexing and mechanical stresses without losing barrier performance, unlike rigid ceramic coatings.
Solution Approach 2:
The patent changes the material parameters from rigid ceramic to flexible polymers, adjusting the thickness and composition of each layer to achieve the desired barrier properties while maintaining mechanical flexibility. The specific polymer composition and layer thicknesses are optimized to balance barrier performance with mechanical stress resistance.
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 film achieves oxygen transmission rates below 0.05 cm3/m2/24 h/atm and maintains barrier properties after flexing, being transparent, cost-effective, and recyclable, with improved adhesion and reduced metal usage compared to traditional methods.
Implementation Method 1
applying the inorganic layer (3,30) of the one or more barrier layers (6,60) on the organic layer (2,20) by electron beam vacuum deposition
Data Source
AI summary
The present invention is related to a flexible multilayer packaging film with high gas barrier properties comprising:one or more support layer(s) (1,10);one or more barrier layer(s) (6,60), each of the one or more barrier layer(s) (6,60) comprising an organic layer (2,20) and an inorganic layer(3,30); wherein said multilayer film has an oxygen transmission rate of less than 0.1 cm3/m2/24 h/atm, preferably less than 0.05 cm3/m2/24 h/atm, most preferably less than 0.03 cm3/m2/24 h/atm measured at 23° C. and 50% relative humidity.