Multilayer Container Oxygen Barrier Resin Design
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Solution Overview
Problem
The existing multilayer packaging containers have insufficient oxygen-barrier performance and oxygen absorbability, particularly when subjected to thermal sterilization, and they also suffer from issues related to appearance and disposal.
Innovation Solution
A multilayer container design featuring an oxygen-permeable layer, an oxygen-absorbing adhesive layer, a gas-barrier layer, and a protective layer, with specific resin compositions and thickness ratios to enhance oxygen-barrier performance and absorbability without compromising appearance or thermoformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If amorphous polyamide is incorporated in the gas-barrier layer to improve molding processability, then the container can be thermoformed, but the oxygen-barrier performance and oxygen absorbability are insufficient
Solution Approach 1:
The gas-barrier layer uses a composite polyamide resin system combining crystalline polyamide (providing oxygen barrier and thermal stability) with controlled amorphous polyamide content (providing thermoformability). This composite approach achieves both molding processability and oxygen-barrier performance by leveraging the complementary properties of different polyamide components.
Solution Approach 2:
The invention optimizes the composition parameters of the polyamide resin by specifying that metaxylylenediamine units constitute 70 mol% or more of the diamine units, and controlling the amorphous polyamide content to 5-30 mass%. These parameter adjustments enhance both the oxygen-barrier performance and thermoformability of the gas-barrier layer.
2Reliability
If the deoxidant composition content is increased to improve oxygen absorbability, then oxygen absorbability improves, but the adhesive strength and appearance may deteriorate
Solution Approach 1:
The invention optimizes the deoxidant composition content parameter within the specific range of 5-50 mass% in the oxygen-absorbing adhesive layer. This controlled parameter adjustment ensures sufficient oxygen absorbability while maintaining adhesive strength and appearance quality, avoiding the deterioration that would occur with excessive deoxidant content.
Solution Approach 2:
The oxygen-absorbing adhesive layer combines deoxidant composition with thermoplastic resin and adhesive resin in specific proportions. This composite structure allows the layer to simultaneously provide oxygen absorption, adhesion, and aesthetic appearance, resolving the contradiction between oxygen absorbability and adhesive strength.
3Strength
If the adhesive resin content is increased to improve layer bonding, then adhesive strength improves, but the oxygen absorbability and molding processability may worsen
Solution Approach 1:
The invention controls the adhesive resin content within 20-70 mass% of the oxygen-absorbing adhesive layer composition. This parameter optimization ensures adequate adhesive strength for layer bonding while leaving sufficient space for deoxidant composition (5-50 mass%) to maintain oxygen absorbability, and for thermoplastic resin to ensure molding processability.
Solution Approach 2:
The oxygen-absorbing adhesive layer is designed with differentiated local functions: the thermoplastic resin component provides molding processability, the adhesive resin component provides bonding strength, and the deoxidant composition component provides oxygen absorbability. This local quality differentiation allows each component to optimize its specific function without compromising the others.
4Reliability
If the oxygen-absorbing adhesive layer thickness is increased to improve oxygen absorbability, then oxygen absorbability improves, but the outward appearance on thermoforming worsens
Solution Approach 1:
The invention optimizes the thickness of the oxygen-absorbing adhesive layer within 10-30% of the total container thickness. This parameter control ensures sufficient oxygen absorption capacity while maintaining thin enough dimensions to preserve good outward appearance after thermoforming, avoiding the aesthetic deterioration that would result from excessive layer thickness.
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 container achieves improved oxygen-barrier performance and absorbability, suitable for thermal sterilization, while maintaining appearance quality and convenience in disposal.
Implementation Method 1
an oxygen-absorbing adhesive layer (B) containing, as the main components thereof, an oxygen-absorbing resin composition (b1) containing a deoxidant composition (b1-i)
Implementation Method 2
a gas-barrier layer (C) containing a gas-barrier resin as the main component thereof
Implementation Method 3
an oxygen-permeable layer (A) containing an oxygen-permeable resin as the main component thereof
Data Source
AI summary
A multilayer container having a layer configuration of 3 or more layers including, as layered in that order from an inner layer to an outer layer, an oxygen-permeable layer (A) containing an oxygen-permeable resin as the main component thereof, an oxygen-absorbing adhesive layer (B) containing, as the main components thereof, an oxygen-absorbing resin composition (b1) containing a deoxidant composition (b1-i) and a thermoplastic resin (b1-ii) and an adhesive resin (b2), and a gas-barrier layer (C) containing a gas-barrier resin as the main component thereof, wherein the gas-barrier resin is a polyamide resin (X) including a diamine unit containing a metaxylylenediamine unit in an amount of 70 mol% or more and a dicarboxylic acid unit containing 75 to 96 mol% of an α,ω-linear aliphatic dicarboxylic acid unit having 4 to 20 carbon atoms and 25 to 4 mol% of an aromatic dicarboxylic acid unit, the content of the deoxidant composition (bl-i) in the oxygen-absorbing adhesive layer (B) is 5 to 50% by mass relative to 100% by mass of the material constituting the oxygen-absorbing adhesive layer (B), the content of the adhesive resin (b2) is 20 to 70% by mass relative to 100% by mass of the material constituting the oxygen-absorbing adhesive layer (B), and the thickness of the oxygen-absorbing adhesive layer (B) is 10 to 30% of the total thickness of the multilayer container.