Gas Barrier Laminate Using Composite Coating
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Solution Overview
Problem
Current gas barrier laminates for packaging materials, such as those for foods and medicines, do not achieve optimal gas barrier properties, particularly in preventing oxygen and water vapor transmission.
Innovation Solution
A laminated structure comprising a barrier layer with a water-soluble resin, such as polyvinyl alcohol, and a condensate of hydrolyzed metal alkoxide, combined with an inorganic material layer and a base material, where the barrier layer has a low frictional force due to uniform dispersion of these components, achieved through a high-pressure dispersion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional coating agent is used to form a barrier layer, then the laminate structure can be formed, but the gas barrier properties are insufficient
Solution Approach 1:
The patent uses a composite coating agent containing both water-soluble resin and hydrolyzed metal alkoxide. The water-soluble resin forms a continuous matrix while the hydrolyzed metal alkoxide creates a condensed inorganic network structure within the coating film. This composite structure provides excellent gas barrier properties by creating a tortuous path for gas molecules, combining the advantages of both organic and inorganic materials.
Solution Approach 2:
The patent changes the chemical composition parameters of the coating agent by incorporating hydrolyzed metal alkoxide alongside water-soluble resin. This parameter change transforms the coating film structure from a simple organic polymer matrix to a composite structure with inorganic condensate, significantly improving gas barrier performance while maintaining manufacturability through conventional coating processes.
2Reliability
If the barrier layer uses simple resin coating, then the manufacturing process is simple, but the frictional force is high and gas barrier properties are poor
Solution Approach 1:
The coating agent comprises a composite system where water-soluble resin provides film formation and adhesion, while hydrolyzed metal alkoxide forms a condensed inorganic network. This composite structure creates low frictional force on the film surface and provides excellent gas barrier properties simultaneously, without requiring complex multi-step coating processes.
Solution Approach 2:
The patent applies local quality by creating a condensed inorganic network structure specifically within the coating film matrix. The hydrolyzed metal alkoxide condenses to form a three-dimensional inorganic network that locally enhances gas barrier properties and reduces surface friction, while the water-soluble resin maintains overall film integrity and processability.
3Reliability
If a multi-layer laminated structure is created with additional layers, then gas barrier properties improve, but the manufacturing complexity and cost increase
Solution Approach 1:
Instead of adding multiple separate layers, the patent achieves superior gas barrier properties within a single barrier layer by using a composite coating agent. The combination of water-soluble resin and hydrolyzed metal alkoxide creates a multi-phase structure within the coating film itself, providing excellent gas barrier performance without the need for additional laminated layers, thus simplifying the overall laminate structure while maintaining high reliability.
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 resulting gas barrier laminate exhibits excellent gas barrier properties, reducing the deterioration of packaged contents and extending storage periods, thereby minimizing waste and promoting resource conservation.
Implementation Method 1
a barrier layer which comprises a water-soluble resin and a condensate of hydrolyzed metal alkoxide
Implementation Method 2
a condensate of hydrolyzed metal alkoxide
Data Source
AI summary
The present invention provides a gas barrier laminate having a laminated structure comprising a barrier layer, an inorganic material layer and a base material in this order, wherein: the barrier layer includes a water-soluble resin and a condensate of hydrolyzed metal alkoxide; and a frictional force of the barrier layer measured by atomic force microscopy is 3.0 × 10-4 (V) or less.