Multilayer Packaging Structure with Phosphorus-Polymer Adhesion Layer
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Solution Overview
Problem
Conventional multilayer structures used in packaging materials and electronic device protective sheets suffer from decreased interlayer adhesion and gas barrier properties when exposed to physical stresses, such as deformation and high temperature/high humidity conditions, leading to appearance defects like delamination.
Innovation Solution
A multilayer structure comprising a base, a layer containing a phosphorus atom compound and a polymer with hydroxy or carboxyl groups, and an aluminum layer, where the mass ratio of the compound to the polymer is between 15:85 to 99:1, and the aluminum layer is formed through a reaction product of a metal oxide and a phosphorus compound, ensuring high performance and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional multilayer structure with aluminum or aluminum oxide barrier layer is used, then initial gas barrier properties are good, but interlayer adhesion decreases under harsh conditions (high temperature and high humidity) leading to delamination
Solution Approach 1:
The invention uses a composite layer (Y) containing both phosphorus compound particles and polymer particles, rather than a single material. This composite structure provides both gas barrier properties and adhesion to the aluminum layer, resolving the contradiction between maintaining gas barrier performance and preventing delamination under harsh conditions.
Solution Approach 2:
The phosphorus compound particles act as an intermediary between the aluminum layer and the polymer matrix. They chemically react with the aluminum layer to form strong bonds while being embedded in the polymer matrix that provides flexibility and adhesion, thus mediating between the requirements for gas barrier performance and interlayer adhesion.
2Adaptability or versatility
If a conventional multilayer structure is used for retort packaging, then it provides basic protection, but it undergoes delamination and appearance defects after retorting
Solution Approach 1:
The phosphorus compound particles are pre-applied to the aluminum layer before the polymer coating is formed. This preliminary action allows the phosphorus compounds to chemically bond with the aluminum surface, creating a strong adhesive interface that prevents delamination during subsequent retorting processes and maintains appearance quality.
3Quantity of substance
If the aluminum layer is made thinner to reduce material usage, then cost and weight decrease, but gas barrier properties become insufficient under physical stresses
Solution Approach 1:
The composite layer (Y) with phosphorus compound particles and polymer particles creates a synergistic structure where the phosphorus compounds provide enhanced gas barrier properties through their molecular structure, allowing the aluminum layer to be thinner while maintaining sufficient gas barrier performance under physical stresses.
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 high gas barrier properties and resistance to appearance defects even under harsh conditions, such as retorting and physical stresses, while maintaining interlayer adhesion and mechanical integrity.
Implementation Method 1
the layer (Z) is a layer containing a reaction product formed by a reaction between a metal oxide (C) containing aluminum and a phosphorus compound (D)
Implementation Method 2
a coating liquid (S) containing the compound (A), the polymer (B), and the solvent; a layer (Y) formation step including: a step (Y-i) of mixing the compound (A), the polymer (B), and the solvent
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a multilayer structure including a base (X), a layer (Y), and a layer (Z) disposed contiguous to the layer (Y). The layer (Y) includes a compound (A) containing a phosphorus atom and a polymer (B) having a hydroxy group and/or carboxyl group. A mass ratio between the compound (A) and the polymer (B) is 15 : 85 to 99 : 1 in the layer (Y). The layer (Z) is a layer containing aluminum atoms.