Moisture Barrier Laminate with a Quasi-Hygroscopic Interlayer
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Solution Overview
Problem
Existing moisture barrier laminates with inorganic and hygroscopic layers suffer from rapid deactivation of the hygroscopic layer, limiting their ability to maintain effective moisture barrier properties over a long period.
Innovation Solution
Incorporating a quasi-hygroscopic layer between the inorganic and hygroscopic layers, with specific water solubility coefficients, to extend the lifespan of moisture barrier properties without increasing the thickness of the hygroscopic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick organic layer (10 μm or more) is provided between the inorganic barrier layer and hygroscopic layer, then moisture diffusion is enhanced and hygroscopic layer wastage is reduced, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the intermediate layer into two functional segments: a hydrophobic layer (5-20 μm) that diffuses moisture and a quasi-hygroscopic layer (1-10 μm) that captures moisture. This segmentation allows each layer to perform its specific function optimally without requiring excessive thickness, thereby reducing overall device complexity while maintaining reliability.
Solution Approach 2:
The patent employs a composite structure combining hydrophobic resin and quasi-hygroscopic resin in a layered configuration. The hydrophobic layer provides moisture diffusion through its low solubility coefficient, while the quasi-hygroscopic layer with higher solubility coefficient captures moisture. This composite approach achieves effective moisture barrier properties with reduced layer thickness compared to a single thick organic layer.
2Duration of action of stationary object
If the hygroscopic layer is made thicker to extend service life, then moisture barrier properties are maintained longer, but the loss of substance and cost increase
Solution Approach 1:
The quasi-hygroscopic layer acts as a preliminary moisture capture layer positioned between the inorganic barrier layer and the hygroscopic layer. It pre-absorbs moisture that penetrates the inorganic layer, preventing direct contact with and rapid consumption of the hygroscopic layer. This preliminary action extends the service life of the hygroscopic layer material, reducing substance loss.
Solution Approach 2:
The quasi-hygroscopic layer serves as an intermediary between the inorganic barrier layer and the hygroscopic layer. With a water solubility coefficient higher than the inorganic layer but lower than the hygroscopic layer, it mediates moisture transfer, capturing moisture before it reaches the hygroscopic layer. This intermediary function protects the hygroscopic layer from rapid deactivation and extends its operational duration.
3Duration of action of stationary object
If a quasi-hygroscopic layer with higher water solubility is provided between inorganic and hygroscopic layers, then moisture barrier performance is extended, but the manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes the water solubility coefficient parameter of the quasi-hygroscopic layer to be higher than the inorganic barrier layer but lower than the hygroscopic layer. This parameter change creates a gradual moisture transfer gradient that extends barrier performance. The specified thickness range (1-10 μm) provides sufficient moisture capture capacity while remaining manufacturable, balancing performance extension with manufacturing precision requirements.
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 quasi-hygroscopic layer effectively prolongs the moisture barrier performance by suppressing hygroscopic layer deactivation, allowing for enhanced moisture barrier properties over an extended period at a lower cost.
Implementation Method 1
an inorganic barrier layer... being disposed closer to a high moisture atmosphere than the hygroscopic layer
Implementation Method 2
a quasi-hygroscopic layer... having a water solubility coefficient at 85°C smaller than that of the hygroscopic layer
Implementation Method 3
a hygroscopic layer... on a plastic base material
Data Source
Figure 1
AI summary
Disclosed herein is a moisture barrier laminated film 10 including an inorganic barrier layer 3 and a hygroscopic layer 5 on a plastic base material 1. The inorganic barrier layer 5 is disposed closer to a high moisture atmosphere than the hygroscopic layer 5. The moisture barrier laminated film is characterized in that a quasi-hygroscopic layer 7 is provided between the inorganic barrier layer 3 and the hygroscopic layer 5, and water solubility coefficients in the quasi-hygroscopic layer 7 and in the hygroscopic layer 5 satisfy a condition represented by the following expression (1): 0.1S2 ≤ S1 < S2 (1), where S1 is a water solubility coefficient at 85°C in the quasi-hygroscopic layer, and S2 is a water solubility coefficient at 85°C in the hygroscopic layer.