Multilayer Barrier Film Segmentation for Oxygen Transmission
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Solution Overview
Problem
Current multilayer packaging films with oxygen barrier layers, such as those using EVOH, often have higher Oxygen Transmission Rates (OTR) than desired, necessitating the development of enhanced barrier films with improved efficiency while maintaining or reducing the thickness of barrier layers.
Innovation Solution
A multilayer barrier film structure comprising a polyolefin core layer with barrier layers on both sides and adjacent polyolefin layers, where the barrier layer thickness ranges from 1 µm to 25 µm, and optionally includes tie layers for enhanced adhesion and compatibility, prepared through processes like blown film or cast film extrusion or lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single barrier layer is used to achieve oxygen barrier properties, then the film thickness can be reduced, but the Oxygen Transmission Rate (OTR) increases becoming greater than 0.2 cm³/(m²·day·atm)
Solution Approach 1:
The single barrier layer is divided into multiple barrier layers (at least two) separated by a polyolefin core layer. This segmentation allows each barrier layer to contribute to oxygen blocking while the polyolefin core layer provides structural support, achieving lower OTR values (≤0.2 cm³/(m²·day·atm)) with reduced overall film thickness compared to single-layer designs.
Solution Approach 2:
The invention creates a composite multilayer structure combining barrier materials (EVOH, polyamide, polyester) with polyolefin core layers. This composite approach leverages the superior oxygen barrier properties of EVOH/polyamide while the polyolefin provides mechanical strength and processability, achieving both thin profile and high barrier performance simultaneously.
2Reliability
If the thickness of the barrier layer is increased to reduce OTR, then the oxygen barrier property improves, but the film complexity and manufacturing difficulty increase
Solution Approach 1:
Instead of using a single thick barrier layer, the structure segments the barrier function across multiple thinner layers (each 1-25 μm) separated by polyolefin core layers. This segmentation reduces the complexity of manufacturing single thick layers while achieving equivalent or superior barrier properties through the cumulative effect of multiple layers.
Solution Approach 2:
The polyolefin core layers are strategically positioned between barrier layers to provide localized structural support and processability where needed, while the barrier layers are positioned specifically for oxygen blocking. This local optimization allows each layer to perform its specialized function without requiring the entire film structure to be overly complex.
3Strength
If multiple polyamide layers are added to improve impact resistance and flex crack resistance, then the mechanical properties improve, but the OTR increases beyond acceptable levels
Solution Approach 1:
The invention creates a composite structure where polyolefin core layers (providing mechanical strength and impact resistance) are combined with barrier layers (EVOH, polyamide, polyester for oxygen blocking). This composite approach allows the polyolefin to handle mechanical stresses while the barrier layers maintain low OTR (≤0.2 cm³/(m²·day·atm)), solving the trade-off between strength and barrier properties.
Solution Approach 2:
The structure segments the mechanical support function from the barrier function by placing polyolefin core layers between barrier layers. This allows the polyolefin to provide impact and flex crack resistance without compromising the oxygen barrier properties of the barrier layers, as each layer type is optimized for its specific function.
Data Source
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AI summary
The present disclosure discloses multilayer barrier (F) comprising: (a) at least one polyolefin core layer (A); (b) at least one barrier layer (B) on both the sides of the core layer; and (c) at least one polyolefin layer (C) adjacent to the at least one barrier layer as shown in Fig.1, wherein the at least one barrier layer individually has thickness in the range of 1 m 25 m. It also discloses a process of preparing the multilayer barrier film. Additionally, a laminate comprising the multilayer barrier film of the present disclosure and a process of preparing the laminate is discussed. Furthermore, an article comprising the multilayer barrier film or the laminate of the present disclosure is also disclosed.