Multilayer Bottle Barrier Layer Control Against Filling Delamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multilayer bottles experience delamination issues due to mechanical and thermal impacts during filling, transportation, and dropping, and existing methods to improve delamination resistance compromise gas-barrier properties or increase production costs.
Innovation Solution
A method involving a multilayer bottle structure with specific conditions for the barrier layer, including a glass transition point of 50°C to 100°C and water content less than 1% by weight, using thermoplastic polyester resin for outermost and innermost layers, and a polyamide B with high gas-barrier properties for the barrier layer, to enhance interlaminar bonding strength and prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multilayer bottles are made with barrier layers to improve gas-barrier property, then gas-barrier property is improved, but delamination occurs between layers during filling and transportation
Solution Approach 1:
The invention controls specific parameters of the barrier layer: glass transition point (Tg) between 50-100°C and water content (Wb) ≤ 1% by weight. By optimizing these parameters, the barrier layer achieves both good gas-barrier property and resistance to delamination during filling and transportation
Solution Approach 2:
The invention uses composite material structure with specific resin compositions for each layer. The barrier layer is made from polyamides (PA6, PA66, PA11, PA12) or their copolymers blended with other resins to achieve optimal balance between gas-barrier property and interlaminar bonding strength
2Reliability
If polyamide MXD6 is used in barrier layer to improve oxygen-barrier property, then oxygen-absorbing rate is improved, but costs increase due to transition metal-based catalyst addition
Solution Approach 1:
The invention replaces expensive polyamide MXD6 with more economical polyamides such as PA6, PA66, PA11, or PA12, or their copolymers. These alternative materials achieve satisfactory oxygen-barrier property without requiring expensive transition metal-based catalysts, thereby reducing production costs while maintaining functional performance
3Strength
If considerable amount of amorphous polyamides is added to prevent crystallization, then delamination resistance is improved, but gas-barrier property deteriorates
Solution Approach 1:
The invention optimizes the crystallization rate parameter of the barrier layer to be within 5-50%, avoiding both complete crystallization and complete amorphous states. This controlled partial crystallization maintains good gas-barrier property while achieving sufficient delamination resistance through proper resin selection and formulation
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 method effectively prevents delamination and maintains excellent gas-barrier properties, allowing for various filling methods, including hot filling, while reducing production costs and improving the shelf life of contents.
Implementation Method 1
the glass transition point and water content of the barrier layer are controlled within specific ranges to enhance interlaminar bonding strength and prevent delamination
Implementation Method 2
a method for preventing delamination of multilayer bottles owing to mechanical and thermal impact upon filling, upon transportation or upon dropping
Implementation Method 3
the resultant multilayer bottle exhibits a poorer gas barrier property than those using the polyamide MXD6 only
Data Source
AI summary
There is provided a method for filling a multilayer bottle including outermost and innermost layers and at least one barrier layer interposed between the outermost and innermost layers, with a material to be stored therein. In the filling method, the material to be stored is filled in the multilayer bottle having the barrier layer satisfying a specific glass transition point (Tg) and a specific water content as measured by a Carl-Fisher method at 230° C. for 30 min. The multilayer bottle obtained by the filling method of the present invention hardly undergoes delamination between the layers owing to dropping or impact, and is applicable to a filling method such as hot filling.