Molded Article Phase-Separated Structure Gas Barrier
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Solution Overview
Problem
Aliphatic polyester-based resins have insufficient oxygen barrier properties, making them unsuitable for use alone as packaging materials for contents that may undergo oxidative deterioration, such as food and drugs. Additionally, the poor adhesiveness between aliphatic polyester-based resins and polyvinyl alcohol-based resins complicates the production of laminates with improved gas barrier properties.
Innovation Solution
A molded article is proposed, comprising a resin layer with a phase-separated structure. This structure includes a continuous phase of aliphatic polyester-based resin and a ribbon-like dispersed phase of polyvinyl alcohol-based resin. The resin layer is produced by dry-blending and molding pellets of both resins, ensuring a significant difference in melt viscosity between them, which facilitates the formation of a robust gas barrier layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aliphatic polyester-based resin is used as packaging material, then biodegradability and strength are improved, but oxygen barrier properties deteriorate
Solution Approach 1:
The invention uses a composite resin composition containing both aliphatic polyester-based resin (providing biodegradability and strength) and polyvinyl alcohol-based resin (providing oxygen barrier properties). This composite approach allows the material to simultaneously achieve both biodegradability and good oxygen barrier properties, resolving the contradiction between these two properties.
2Object-affected harmful factors
If aliphatic polyester-based resin and polyvinyl alcohol-based resin are laminated to improve gas barrier properties, then oxygen barrier properties are improved, but interlayer adhesiveness deteriorates
Solution Approach 1:
Instead of laminating two separate layers (which would require good interlayer adhesiveness), the invention merges both resins into a single mixed resin composition that forms an integrated structure. The polyvinyl alcohol-based resin dispersed in the aliphatic polyester-based resin matrix creates gas barrier properties throughout the material without requiring separate laminated layers, thus eliminating the adhesion problem.
3Object-affected harmful factors
If multilayer film forming machine and multilayer sheet molding machine are used to produce laminate, then gas barrier properties are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention creates a universal resin composition that can be processed using standard single-layer molding equipment. The mixed resin composition inherently provides gas barrier properties through its internal structure, eliminating the need for specialized multilayer film forming machines or multilayer sheet molding machines, thus simplifying the manufacturing process 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 resulting molded article exhibits excellent gas barrier properties, including a low oxygen transmission rate, without the need for a specially laminated gas barrier layer. Additionally, both aliphatic polyester-based resin and polyvinyl alcohol-based resin are biodegradable, making the molded article suitable for environmentally friendly packaging solutions.
Implementation Method 1
the resin layer has a resin phase-separated structure having a continuous phase including the aliphatic polyester-based resin (A) as a main component, and a ribbon-like dispersed phase including the polyvinyl alcohol-based resin (B) as a main component
Implementation Method 2
the molded article exhibits excellent gas barrier properties, including a low oxygen transmission rate
Data Source
AI summary
As a molded article that has gas barrier properties even if a gas barrier layer is not provided and that also has molding stability and biodegradability, there is proposed a molded article containing an aliphatic polyester-based resin (A) and a polyvinyl alcohol-based resin (B) as main component resins, wherein the molded article has a resin phase-separated structure having a continuous phase including the aliphatic polyester-based resin (A) as a main component, and a ribbon-like dispersed phase including the polyvinyl alcohol-based resin (B) as a main component.