Multilayer Packaging Structure Maintaining Gas Barrier After Extrusion Lamination

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

The existing multilayer structures used in packaging materials experience a deterioration in gas barrier properties when subjected to extrusion coating lamination, necessitating a solution that maintains high performance even after this process.

Innovation Solution

A multilayer structure comprising a base, a layer containing aluminum atoms, and a layer with a phosphorus-containing compound, where the thermoplastic resin includes an α-olefin unit, and a polymer with functional groups such as phosphonic acid, is used, with the layers formed contiguous to each other and the thermoplastic resin applied by extrusion coating lamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If extrusion coating lamination is applied to the layered product, then additional properties such as heat-sealing properties are imparted, but the gas barrier properties deteriorate

Engineering Contradiction:
Improveheat-sealing propertiesVSAvoidgas barrier properties
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary action by forming a protective layer containing phosphorus compound on the aluminum-containing layered product before subjecting it to extrusion coating lamination. This pre-formed layer prevents the deterioration of gas barrier properties that would otherwise occur during the subsequent lamination process. The phosphorus compound layer acts as a protective barrier that maintains the integrity of the underlying gas barrier structure.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent employs composite materials by creating a multilayer structure that combines different materials with complementary properties: a base layered product containing aluminum for gas barrier properties, and an additional layer containing phosphorus compound for protective functions. This composite structure allows the material to simultaneously achieve heat-sealing capability from the lamination while maintaining gas barrier properties through the phosphorus-containing protective layer.

Inventive Principle:
Principle #40Composite materials

2Reliability

If a gas barrier layer containing aluminum is formed on a plastic film, then light shielding and gas barrier properties are achieved, but the film cannot be visually inspected and is not microwave-safe

Engineering Contradiction:
Improvegas barrier propertiesVSAvoidvisual recognition and microwave heating
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by creating distinct layers with different properties: the aluminum-containing layer provides gas barrier and light shielding properties where needed, while the phosphorus compound-containing layer provides transparency and microwave safety in its region. This spatial differentiation of functions allows the multilayer structure to simultaneously achieve opacity/gas barrier in the aluminum layer and transparency/microwave compatibility in the phosphorus layer.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent uses composite materials to combine the advantages of different materials: aluminum provides excellent gas barrier properties, while the phosphorus compound provides transparency and microwave safety. The composite multilayer structure integrates these materials so that the final product achieves both gas barrier performance and visual inspection capability, as well as microwave compatibility.

Inventive Principle:
Principle #40Composite materials

3Adaptability or versatility

If a transparent gas barrier layer is formed using aluminum oxide particles and phosphorus compound, then visual recognition and microwave heating are enabled, but the gas barrier properties may not be sufficient compared to aluminum-deposited films

Engineering Contradiction:
Improvevisual recognition and microwave heatingVSAvoidgas barrier properties
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges (combining) multiple approaches by integrating both aluminum-containing layers and phosphorus compound-containing layers into a single multilayer structure. This combination allows the system to achieve the transparency and microwave safety associated with phosphorus compounds while simultaneously obtaining the superior gas barrier properties of aluminum, thereby resolving the trade-off between transparency and gas barrier performance.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite materials by creating a multilayer structure that combines aluminum-containing layers with phosphorus compound-containing layers. This composite approach allows the material to simultaneously achieve transparency and microwave safety from the phosphorus layer while maintaining high gas barrier properties from the aluminum layer, overcoming the limitations of using either material alone.

Inventive Principle:
Principle #40Composite materials

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 maintains excellent gas barrier properties with an oxygen transmission rate of 2 mL/(m2·day·atm) or less at 20° C. and 85% RH, even after extrusion coating lamination, enhancing resistance to physical stresses and maintaining appearance.

Implementation Method 1

an extrusion coating lamination apparatus for producing a laminated film by applying an adhesive onto one surface of a multilayered product and laminating a molten thermoplastic resin onto the adhesive

Methodology Applied
Scientific EffectExtrusion: Extrusion

Implementation Method 2

a layer (Z) containing an aluminum atom, wherein a multilayer structure includes a layered product and a layer (H) stacked on the layered product

Methodology Applied
Scientific EffectGas barrier:

Implementation Method 3

a layer (Y) containing a compound (A) containing a phosphorus atom, wherein a multilayer structure includes a layered product and a layer (H) stacked on the layered product

Methodology Applied
Scientific EffectGas barrier:

Implementation Method 4

The multilayer structure maintains excellent gas barrier properties with an oxygen transmission rate of 2 mL/(m2·day·atm) or less at 20° C. and 85% RH

Methodology Applied
Scientific EffectPermeation barrier: Permeation

Data Source

PatentUS10391743B2Multilayer structure, packaging material including the same, and method for producing said multilayer structure
Publication Date: 2019.08.27 KURARAY CO LTD
  • US10391743B2 patent drawing
  • US10391743B2 patent drawing
  • US10391743B2 patent drawing

AI summary

The present invention provides a novel multilayer structure including a layered product capable of maintaining high performance even after being subjected to extrusion coating lamination. The present invention relates to a multilayer structure including a layered product and a layer (H) stacked on the layered product. The layered product includes a base (X), a layer (Z) containing an aluminum atom, and a layer (Y) containing a compound (A) containing a phosphorus atom. The layer (H) contains a thermoplastic resin (U), and the thermoplastic resin (U) is a polymer containing an α-olefin unit.