Gas Barrier Packaging Material Precursor Adhesion Layer Design
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Solution Overview
Problem
Conventional gas barrier packaging materials face issues with adhesion strength, resistance to abuse, and stability under high-temperature and high-pressure conditions, such as retort treatment, and require specialized coating equipment for production.
Innovation Solution
A gas barrier packaging material precursor comprising a support with an adhesion layer containing a silicon compound and a barrier layer formed adjacent to a protective layer, where the protective layer includes a polyvalent metal compound and a dispersant, allowing for stable production without specialized coating equipment and maintaining effective gas barrier properties after retort treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polycarboxylic acid polymer layer and a polyvalent metal compound-containing layer are laminated and reacted to form a polyvalent metal salt, then oxygen gas barrier properties under high humidity conditions are improved, but adhesion strength may be insufficient causing delamination
Solution Approach 1:
The patent introduces a specific adhesive layer containing silane coupling agents (such as γ-aminopropyltriethoxysilane or γ-isocyanatepropyltriethoxysilane) as intermediary substances between the substrate and the polycarboxylic acid polymer layer. This adhesive layer acts as a mediator that chemically bonds to both the substrate and the polymer layer, ensuring sufficient adhesion strength while allowing the polycarboxylic acid polymer layer to maintain its oxygen barrier function under high humidity conditions.
2Reliability
If retort treatment is applied to ensure gas barrier properties, then oxygen transmission is reduced, but the packaging material requires specialized coating equipment for production
Solution Approach 1:
The patent incorporates adhesive layers with silane coupling agents during the initial coating process, before the final packaging material is formed. This preliminary action ensures that the adhesion and barrier properties are established in advance, eliminating the need for complex specialized coating equipment and subsequent retort treatment to achieve gas barrier properties.
3Reliability
If a polyvalent metal salt layer is formed to provide gas barrier properties, then oxygen transmission is reduced, but resistance to abuse such as bending and stretching is poor
Solution Approach 1:
The patent creates a composite structure where the polycarboxylic acid polymer layer forms a polyvalent metal salt with the polyvalent metal compound, embedded within a matrix containing acrylic polyol and isocyanate compound. This composite material structure provides both the oxygen barrier properties from the metal salt and the flexibility and abuse resistance from the polymer matrix, allowing the material to withstand bending and stretching while maintaining gas barrier performance.
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 enables the production of gas barrier packaging materials with improved adhesion strength, abuse resistance, and stability under high-temperature and high-pressure conditions, without the need for specialized coating equipment, while maintaining excellent oxygen gas barrier properties.
Implementation Method 1
an adhesion layer containing a composite of a silicon compound having any one of an isocyanate group, an amino group, and a mercapto group, or a hydrolysate of the compound
Implementation Method 2
packaging materials are desired to have properties of not transmitting gases, such as oxygen and water vapor, therethrough (gas barrier properties)
Implementation Method 3
the protective layer is formed of a coating liquid containing a polyvalent metal compound, a polyester resin, and a dispersant
Implementation Method 4
a silicon compound having any one of an isocyanate group, an amino group, and a mercapto group, or a hydrolysate of the compound
Data Source
AI summary
A gas barrier packaging material precursor, includes a support; an adhesion layer on one surface of the support; and a barrier layer and a protective layer formed adjacent each other on the adhesion layer. The adhesion layer contains a silicon compound composite. The protective layer is formed of a coating liquid containing a polyvalent metal compound, a polyester resin, and a dispersant, with the polyvalent metal compound being about 40 to about 90 mass % relative to 100 mass %. When the barrier layer is separated from the gas barrier packaging material precursor to measure an infrared absorption spectrum of the barrier layer by a transmission method, a ratio (α/β) of a maximum peak height (α) of absorbance in a range of about 1490 to about 1659 cm−1 to a maximum peak height (β) of absorbance in a range of about 1660 to about 1750 cm−1 is less than about 1.