Polyolefin Composite Film With Graphene Barrier Masterbatch
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Solution Overview
Problem
Existing high-barrier composite films are non-transparent due to metal foils, difficult to recycle, and expensive alternative films hinder recycling and reuse, while polyolefins like PE and PP have poor barrier properties against water vapor and oxygen.
Innovation Solution
A high-barrier polyolefin composite film is developed, comprising an outer film, a water-barrier layer, a high-barrier PVA coating layer, and an inner film, using modified PE or PP films with a water- and oxygen-barrier masterbatch containing polycarbonate, EVA, single-layer graphene, and polyhedral oligomeric silsesquioxane, along with a water-barrier adhesive and adhesive layer to enhance barrier properties and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal aluminum foil is used to achieve high barrier properties, then barrier performance against oxygen and water is improved, but transparency is lost and recyclability becomes difficult
Solution Approach 1:
The patent removes the metal aluminum foil layer from the traditional BOPET/AL/PE composite structure and replaces it with organic barrier films (EVOH, silicon oxide, alumina) and a PVA coating layer. This extraction of the metal component enables transparency while maintaining barrier properties through alternative materials that can be more easily recycled with plastic layers.
Solution Approach 2:
The patent creates a multi-layer composite structure combining different plastic materials (PET, EVOH, PE, PVA) with specific functional properties. Each layer contributes to overall performance: PET provides mechanical strength, EVOH provides oxygen barrier, PE provides moisture barrier and sealability, and PVA enhances barrier properties. This composite approach achieves high barrier performance without metal foils.
2Illumination intensity
If expensive barrier films (EVOH, silicon oxide, alumina) are introduced to improve transparency and barrier properties, then transparency is improved, but cost increases and recyclability is hindered
Solution Approach 1:
The patent modifies the inner PE film by adding a masterbatch containing specific proportions of barium sulfate (50-70 parts), titanium dioxide (20-40 parts), and zinc oxide (10-30 parts). This parameter change in composition creates a filled PE layer that provides enhanced barrier properties against oxygen and water vapor while maintaining transparency and compatibility with PE recyclability streams.
Solution Approach 2:
The patent uses conventional, cost-effective plastic materials (PET, EVOH, PE, PVA) that are already widely recycled rather than expensive or novel materials. These materials have established recycling infrastructure, making the composite film economically viable and environmentally sustainable despite the multi-layer complexity.
3Ease of manufacture
If single-material PE or PP film is used to improve recyclability, then recyclability is improved, but barrier properties against water vapor and oxygen deteriorate
Solution Approach 1:
The patent embeds a PVA coating layer within the PE film structure, creating a nested configuration where the PVA layer (providing barrier properties) is contained within the PE matrix (providing recyclability). This nested structure allows the inner PE film to be recycled with PE streams while the PVA coating provides the necessary barrier enhancement.
Solution Approach 2:
The patent applies different functional properties to different regions of the film: the outer PET layer provides mechanical strength and transparency, the EVOH layer provides oxygen barrier, the PE layers provide moisture barrier and sealability, and the PVA coating provides additional barrier enhancement. Each region is optimized for its specific function while maintaining overall recyclability.
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 composite film achieves high transparency, strong environmental stress cracking resistance, and excellent barrier properties against water vapor and oxygen, facilitating easy recycling without affecting transparency or recyclability.
Implementation Method 1
the single-layer graphene sheets are uniformly dispersed in the modified inner PE film, thereby blocking the permeability of water vapor and oxygen and improving barrier properties
Implementation Method 2
During the blending, extrusion and film blowing process, the polycarbonate and the EVA undergo a transesterification reaction in a molten state to form a connected or cross-linked copolymer at an interface
Implementation Method 3
by virtue of steric hindrance produced by the polyhedral oligomeric silsesquioxane absorbed on the surface of single-layer graphene, the single-layer graphene is dispersed more uniformly and stably
Implementation Method 4
an outer film, a water-barrier layer, a high-barrier PVA coating layer, an adhesive layer, and an inner film
Data Source
AI summary
The present application discloses a high-barrier polyolefin composite film, including, from the outside to the inside, an outer PE film, a water-barrier layer, a high-barrier PVA coating layer, an adhesive layer, and an inner PE film, wherein the inner PE film includes the following raw materials in percentage by weight: 10-20% of HDPE, 30-50% of MDPE, 20-26% of LLDPE, 10-20% of LDPE, 8-12% of a water- and oxygen-barrier masterbatch, and 1-3% of an auxiliary agent; the water- and oxygen-barrier masterbatch includes the following raw materials in parts by weight: 10-20 parts of polycarbonate, 0.1-0.3 parts of a compatibilizer, 10-20 parts of an ethylene-vinyl acetate copolymer (EVA), 1-2 parts of single-layer graphene, and 1-2 parts of polyhedral oligomeric silsesquioxane.