Hybrid Polymer Barrier Layer for Packaging

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Solution Overview

Problem

Current plastic packaging materials have insufficient barrier properties against oxygen and water vapor migration, necessitating additional barrier layers and posing challenges for the shelf life and safety of food, cosmetic, and pharmaceutical products.

Innovation Solution

A hybrid polymer composite is developed, comprising silanes, metal compounds, and specific organic groups, which are hydrolytically condensed and organically crosslinked to create a flexible, high-density barrier layer with improved barrier properties, suitable for use in packaging materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If barrier layers are incorporated into plastic packaging to improve barrier properties, then oxygen and water vapor migration is reduced, but device complexity and manufacturing complexity increase

Engineering Contradiction:

Improvebarrier propertiesVSAvoidpackaging structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the barrier function and the structural function into a single hybrid polymer layer. This layer integrates inorganic barrier particles (such as clay, silica, or metal oxides) within a polymer matrix, creating a composite material that simultaneously provides mechanical strength and high barrier performance against oxygen and water vapor migration, thereby eliminating the need for separate barrier layers

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention employs composite materials by formulating a hybrid polymer consisting of organic polymer components and inorganic barrier particles. This composite structure leverages the advantages of both materials: the polymer provides flexibility and adhesion, while the inorganic particles provide high barrier properties, achieving excellent oxygen and water vapor resistance in a single integrated layer

Inventive Principle:

Principle #40Composite materials

2Reliability

If hybrid polymer network density is increased to improve barrier properties, then oxygen and water vapor migration is reduced, but brittleness increases

Engineering Contradiction:

Improvebarrier propertiesVSAvoidbrittleness

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent optimizes the parameters of the hybrid polymer system by carefully selecting and adjusting the types and amounts of inorganic particles, polymer matrix composition, and particle size distribution. By controlling these parameters, the formulation achieves a dense network structure for high barrier performance while maintaining adequate flexibility and reducing brittleness through proper material selection and ratio optimization

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates local variations in the hybrid polymer structure by distributing inorganic particles non-uniformly within the polymer matrix. The particle concentration and arrangement are optimized locally to create dense barrier regions that block migration pathways, while maintaining continuous polymer phases that provide flexibility and prevent overall brittleness of the material

Inventive Principle:

Principle #3Local quality

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 hybrid polymer composite achieves excellent barrier performance, balancing high network density with low brittleness, enabling flexible and sustainable packaging solutions that can be recycled, and is suitable for various substrates, including paper and plastics, effectively preventing diffusion of substances like oxygen, water vapor, and aromas.

Implementation Method 1

hydrolytically condensing hydrolytically condensable components

Methodology Applied

Scientific EffectHydrolytic condensation: Hydrolysis

Implementation Method 2

organically crosslinking organically crosslinkable components

Methodology Applied

Scientific EffectOrganic crosslinking: Chemical Bonding

Implementation Method 3

exhibiting an excellent balance between high network density and low brittleness... effectively preventing diffusion of substances like oxygen, water vapor, and aromas

Methodology Applied

Scientific EffectDiffusion barrier: Diffusion Barrier

Data Source

PatentEP4269516A1Composition for hybrid polymers having barrier function

Publication Date: 2023.11.01 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

AI summary

Composition containing compounds (A) to (C) in the following proportions, totaling 100 mol percent: (A) at least 30 mol percent of a silane with four hydrolytically condensable groups, (B) at least 30 mol percent of a silane with organically crosslinkable groups and optionally a hydrolytically condensable group, and (C) at least 10 mol percent of a compound of a tetravalent metal with a hydrolytically condensable group; process for producing a hybrid polymer from the composition; hybrid polymer produced therefrom; use of the hybrid polymer as a barrier layer; composite comprising a substrate and the hybrid polymer layer; use of the composite as packaging material.