Multilayer Barrier Structure for Flexible Protective Sheets
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Solution Overview
Problem
Conventional multilayer structures for flexible electronic devices fail to achieve a balance between high water vapor barrier properties and peel strength with respect to sealants, often compromising flexibility due to increased thickness.
Innovation Solution
A multilayer structure comprising a base with layers containing a reaction product of an inorganic phosphorus compound and a metal oxide, laminated with thermoplastic resin layers via adhesive layers, ensuring a total thickness of 15 μm to 120 μm and optimized thermal shrinkage to maintain flexibility and peel strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple films with water vapor barrier properties are laminated to satisfy high water vapor barrier performance, then water vapor barrier properties are improved, but the thickness of the protective sheet becomes great and flexibility is impaired
Solution Approach 1:
The patent applies composite materials by creating a multilayer structure where a base film is combined with inorganic phosphorus compound layers and metal oxide layers. This composite structure achieves superior water vapor barrier properties (moisture permeability of 1.0×10^-2 g/m2·day or less) while maintaining flexibility through controlled total thickness (15-120 μm). The inorganic layers provide barrier functionality without requiring multiple thick polymer films, thus resolving the contradiction between barrier performance and flexibility.
Solution Approach 2:
The patent utilizes parameter changes by precisely controlling the thickness parameters of each layer. The base film thickness is set at 5-100 μm, each inorganic layer thickness is controlled at 5-100 μm, and the total thickness is maintained at 15-120 μm. By optimizing these dimensional parameters, the patent achieves both high water vapor barrier properties and maintained flexibility, directly addressing the technical contradiction.
2Strength
If a film capable of enhancing peel strength with respect to sealant is laminated on the exposed surface, then peel strength is improved, but the thickness increases and flexibility is impaired
Solution Approach 1:
The patent incorporates adhesive layers as part of the composite multilayer structure. These adhesive layers are integrated between the base film and the inorganic phosphorus compound layers, providing enhanced peel strength with respect to sealants while maintaining overall flexibility through the thin total thickness design (15-120 μm). This resolves the contradiction by embedding the adhesive function within the composite structure rather than adding separate thick adhesive films.
3Ease of operation
If film-thinning of members is performed to make the electronic device thin, then flexibility is improved, but water vapor barrier properties and adhesiveness with sealant are compromised
Solution Approach 1:
The patent applies parameter changes by optimizing the thickness of the base film to 5-100 μm and controlling the total thickness to 15-120 μm. Despite this thinning, the patent achieves superior water vapor barrier properties (moisture permeability of 1.0×10^-2 g/m2·day or less) through the inorganic phosphorus compound layers and metal oxide layers. This resolves the contradiction by demonstrating that thin films can maintain high barrier properties through material composition rather than thickness alone.
Solution Approach 2:
The patent uses composite materials to achieve both thinness and high barrier properties. The combination of base film, inorganic phosphorus compound layers, and metal oxide layers creates a composite structure where each component contributes specific functions. This composite approach enables the thin film (15-120 μm total) to achieve water vapor barrier properties that would otherwise require much thicker films, thus resolving the contradiction between thinness/flexibility and 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 solution provides a multilayer structure with superior water vapor barrier properties and peel strength while maintaining flexibility, effectively addressing the limitations of conventional structures.
Implementation Method 1
the at least two layers (Y) contain a reaction product (D) of an inorganic phosphorus compound (BI) with a metal oxide (A) containing an aluminum atom
Implementation Method 2
layers (Z) containing a thermoplastic resin as a principal component and being laminated via each of adhesive layers (I) on both faces of the laminate
Data Source
AI summary
The present disclosure relates to a multilayer structure including: a laminate including a base (X) and at least two layers (Y), the layers (Y) being provided on both faces of the base (X); and layers (Z) containing a thermoplastic resin.