Multilayer Gas Barrier Structure with Phosphorus Polymer
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Solution Overview
Problem
Conventional gas barrier coatings for food packaging suffer from defects such as cracks and pinholes when subjected to physical stresses, leading to a decrease in gas barrier properties during use.
Innovation Solution
A multilayer structure comprising a layer with aluminum atoms and a layer containing a polymer with multiple phosphorus atoms, specifically poly(vinylphosphonic acid), which are contiguously stacked to enhance flexibility and maintain high gas barrier properties under deformation and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional gas barrier coating (aluminum or alumina deposited by vacuum deposition, sputtering, ion plating, or CVD) is applied to a plastic film, then initial gas barrier properties are excellent, but the coating develops cracks and pinholes when subjected to physical stresses such as deformation and impact, causing gas barrier properties to deteriorate during actual use
Solution Approach 1:
The patent applies composite materials by combining aluminum oxide particles with a phosphorus compound to form a coating layer. This composite structure maintains gas barrier properties while improving flexibility, as the phosphorus compound acts as a binder that provides adhesion and flexibility to the rigid aluminum oxide particles, preventing crack formation under physical stress
Solution Approach 2:
The patent changes the chemical composition and bonding characteristics of the coating by introducing a phosphorus compound that forms strong chemical bonds with aluminum oxide particles. This parameter change in chemical composition enhances the coating's ability to withstand deformation and impact while maintaining gas barrier properties
2Strength
If a coating layer containing aluminum oxide particles and phosphorus compound is applied to a plastic film, then flexibility is improved, but the manufacturing process becomes more complex requiring coating application, drying, and heat treatment steps
Solution Approach 1:
The patent merges multiple functions into a single coating layer: the phosphorus compound serves both as a binder to provide flexibility and as a chemical agent to bond with aluminum oxide particles for gas barrier properties. This consolidation reduces the need for separate coating layers for different functions, simplifying the overall manufacturing process
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 multilayer structure effectively maintains excellent gas barrier properties even under physical stresses, as demonstrated by its ability to withstand stretching and maintain low oxygen transmission rates, ensuring better performance in practical applications.
Implementation Method 1
a multilayer structure including at least one base (X), at least one layer (Y), and at least one layer (Z), wherein the layer (Y) contains an aluminum atom, the layer (Z) contains a polymer (E) having a plurality of phosphorus atoms
Data Source
AI summary
A multilayer structure disclosed is a multilayer structure including at least one base (X), at least one layer (Y), and at least one layer (Z). The layer (Y) contains an aluminum atom. The layer (Z) contains a polymer (E) having a plurality of phosphorus atoms. The polymer (E) is a polymer of at least one monomer including a vinylphosphonic acid compound. The multilayer structure includes at least one pair of the layer (Y) and the layer (Z) that are contiguously stacked. The layer (Z) is formed by applying a coating liquid (V) which is a solution of the polymer (E) having a plurality of phosphorus atoms. The multilayer structure disclosed is excellent in gas barrier properties, and can maintain the gas barrier properties at a high level even when subjected to physical stresses such as deformation and impact.