Laminated Bottle Intermittent Barrier Segments Prevent Delamination
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Solution Overview
Problem
The delamination of polyester resin layers in laminated bottles with a gas barrier resin layer, such as ethylene-vinyl alcohol copolymer (EVOH) and nylon resin, leads to poor appearance and decreased product value due to layer separation between the inner, outer, and gas barrier resin layers.
Innovation Solution
A laminated bottle design with gas barrier resin layers arranged at intervals via intermittent portions that extend in the form of ribbons, strips, or annular bodies, ensuring the inner and outer layers are connected in the thickness direction, with the width of these intermittent portions being 1.5 mm or more to prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas barrier resin layers are arranged between inner and outer polyester resin layers, then oxygen permeation prevention properties and oxygen absorptive properties are improved, but layer delamination occurs between the layers
Solution Approach 1:
The gas barrier resin layer is segmented into multiple intermittent portions arranged at intervals along the bottle axis, rather than forming a continuous layer. This segmentation reduces the overall constraint on the inner and outer layers, preventing delamination while maintaining gas barrier functionality through the distributed barrier portions.
Solution Approach 2:
The intermittent portions are strategically positioned to provide local gas barrier protection where most needed, while allowing other regions to maintain layer adhesion. The local concentration of barrier resin provides sufficient oxygen and carbon dioxide protection without requiring complete layer coverage that would cause delamination.
2Stability of the object's composition
If the width of intermittent portions is increased to prevent delamination, then layer stability is improved, but the gas barrier surface area is reduced
Solution Approach 1:
The intermittent portions are designed with a width of 1.5 mm or more, which is sufficient to prevent delamination progression without requiring complete coverage. This partial action approach provides just enough structural stability to constrain the layers while maintaining adequate gas barrier function through the distributed arrangement of multiple portions.
Solution Approach 2:
The intermittent portions are pre-positioned at strategic locations before any delamination can occur, creating preventive constraint points that stop delamination progression in its tracks. These pre-placed barrier segments act as anchors that prevent the spread of layer separation throughout the bottle structure.
3Reliability
If continuous gas barrier resin layer is used, then gas barrier function is maximized, but delamination progresses causing poor appearance
Solution Approach 1:
The continuous gas barrier layer is divided into multiple intermittent portions distributed along the bottle axis. This segmentation maintains sufficient gas barrier functionality through the distributed barrier segments while preventing the delamination that would occur with a continuous constrained layer, thereby preserving bottle appearance.
Solution Approach 2:
The intermittent portion arrangement creates a structured pattern that allows the inner and outer layers to maintain contact and adhesion in the regions between barrier portions, preventing delamination progression and maintaining smooth bottle appearance while still providing effective gas barrier protection through the distributed segments.
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
Provided is a laminated bottle (10) including gas barrier resin layers (1) arranged between an inner layer and an outer layer. The gas barrier resin layers (1) are arranged at an interval from each other via intermittent portions (m3) each extending in the form of a ribbon in a manner such that the inner layer (m1) and the outer layer (m2) are contiguous with each other in the thickness direction in the intermittent portion (m3). A width (C1) of the intermittent portion (m3) in a largest-width region thereof is 1.5 mm or more.