Fluorine Resin Laminate Adhesion via Intermediate Polyethylene Layer
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Solution Overview
Problem
Fluorine-based resin layers in laminates exhibit poor adhesiveness and are prone to peeling when multilayered, compromising the barrier properties and formability of packaging materials.
Innovation Solution
A laminate structure comprising a substrate layer, an intermediate layer with polyethylene resin and modified polyethylene resin, and a fluorine-based resin layer, where the intermediate layer acts as an adhesive, ensuring improved adhesiveness and preventing peeling, with specific thickness ratios and materials like polychlorotrifluoroethylene enhancing water vapor barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a fluorine-based resin layer is used to improve water vapor barrier property, then water vapor permeability is reduced, but adhesiveness to other layers deteriorates and peeling occurs at the interface
Solution Approach 1:
An intermediate layer comprising a polyolefin-based resin and a modified polyolefin-based resin is introduced between the substrate layer and the fluorine-based resin layer. This intermediate layer acts as a mediator that provides both adhesiveness to the substrate and compatibility with the fluorine-based resin layer, preventing peeling while maintaining the water vapor barrier properties of the fluorine layer.
Solution Approach 2:
The laminate is constructed as a composite structure with multiple layers having different functions: the substrate layer provides mechanical strength, the intermediate layer provides adhesion and compatibility, and the fluorine-based resin layer provides water vapor barrier properties. This composite approach allows each layer to optimize its specific function without compromising the overall structure.
2Object-affected harmful factors
If a fluorine-based resin layer is laminated to improve barrier property, then water vapor resistance is enhanced, but formability deteriorates due to peeling at the interface
Solution Approach 1:
The intermediate layer serves as a buffer zone that accommodates the different mechanical properties of the substrate and fluorine-based resin layers. Its composition of polyolefin-based resin and modified polyolefin-based resin provides flexibility and adhesion, allowing the laminate to undergo deep drawing and forming processes without peeling or delamination.
Solution Approach 2:
The intermediate layer's composition parameters are optimized to balance adhesion and flexibility. By controlling the ratio of polyolefin-based resin to modified polyolefin-based resin, and adjusting the thickness of the intermediate layer, the laminate achieves both high water vapor resistance and good formability for deep drawing applications.
3Ease of manufacture
If a simple laminate structure is used to maintain ease of manufacture, then manufacturing complexity is reduced, but adhesiveness and peeling resistance are insufficient
Solution Approach 1:
The laminate is segmented into functionally distinct layers: a substrate layer for mechanical strength, an intermediate layer for adhesion and compatibility, and a fluorine-based resin layer for water vapor barrier properties. This segmentation allows each layer to be optimized for its specific function while maintaining a relatively simple overall manufacturing process using conventional lamination techniques.
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 high water vapor barrier performance without peeling, maintaining formability and preventing content deterioration in packaging applications, such as press-through packages for medicaments.
Implementation Method 1
the intermediate layer acts as an adhesive, ensuring improved adhesiveness and preventing peeling
Implementation Method 2
a fluorine-based resin layer... having a high barrier property to water vapor
Data Source
AI summary
A laminate has a substrate layer, an intermediate layer, and a fluorine-based resin layer in that order, in which the substrate layer contains any one or more kinds of a polyolefin-based resin, a polyester-based resin or a vinyl-based resin, the intermediate layer contains a polyethylene resin and a modified polyethylene resin, and the intermediate layer has a thickness of 5 μm or more and 50 μm or less.