Multilayer Polyolefin-Butyl Barrier Article
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Solution Overview
Problem
Conventional barrier structures and laminates used in applications like inner tubes and food packaging lack elastomeric recovery properties and physical abuse resistance, and are not designed for extended reuse or high-pressure applications, while existing blends like butyl rubber/EPDM do not provide sufficient barrier properties or cost-effectiveness.
Innovation Solution
A multilayer article comprising a first layer of ethylene/a-olefin/diene interpolymer, a second layer of butyl rubber or polyvinylidene chloride, and a third layer of ethylene/a-olefin/diene interpolymer, which offers improved gas barrier properties, temperature resistance, and ozone resistance, allowing for reduced butyl rubber content and lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional barrier structures (foil, polyamide, EVOH, PVDC, PET) are used, then gas barrier properties are improved, but elastomeric recovery properties and physical abuse resistance deteriorate
Solution Approach 1:
The patent uses a composite structure combining polyolefin layers (providing barrier properties) with elastomeric layers (providing flexibility and abuse resistance). Specifically, it employs a multilayer configuration with polyolefin barrier layers and elastomeric adhesive layers that are crosslinked to create a composite material exhibiting both gas barrier properties and elastomeric recovery characteristics.
Solution Approach 2:
The patent employs thin film structures with flexible elastomeric components that can recover after deformation. The elastomeric layers in the composite structure provide flexible shell characteristics enabling the material to return to its original shape after abuse or deformation, while maintaining gas barrier properties through the polyolefin layers.
2Reliability
If conventional laminates are used, then gas barrier properties are improved, but durability for extended use and high-pressure applications deteriorates
Solution Approach 1:
The patent modifies the chemical and physical parameters of the laminate structure by incorporating crosslinked elastomeric adhesives and specific polyolefin compositions. This changes the mechanical and chemical resistance parameters of the laminate, enabling it to withstand high-pressure applications and extended use while maintaining gas barrier properties.
Solution Approach 2:
The patent creates a durable composite laminate combining polyolefin barrier layers with crosslinked elastomeric adhesive layers. This composite structure provides enhanced durability for extended use and high-pressure applications compared to conventional laminates, while maintaining excellent gas barrier properties.
3Reliability
If butyl rubber is used in high content, then barrier properties are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the compositional parameters by reducing butyl rubber content while maintaining barrier properties through the polyolefin/elastomer composite structure. This parameter change lowers manufacturing cost while preserving the required barrier performance through the optimized multilayer configuration.
Solution Approach 2:
The patent uses a composite material system where polyolefin layers provide the primary gas barrier function, reducing dependence on expensive butyl rubber. The elastomeric layers provide adhesion and flexibility, creating a cost-effective composite that achieves barrier properties without requiring high butyl rubber content.
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 achieves better barrier properties than traditional butyl rubber/EPDM blends, enabling thinner, more cost-effective production and enhanced performance in applications requiring extended use and high-pressure resistance.
Implementation Method 1
The article comprises a first layer formed from a first composition comprising an ethylene/a-olefin/diene interpolymer... the article further comprises a third layer formed from a third composition comprising an ethylene/a-olefin/diene interpolymer
Implementation Method 2
the second layer is formed from a second composition comprising a butyl rubber, a polyvinylidene chloride, or a combination thereof
Data Source
AI summary
The invention provides an article comprising a first layer and a second layer, and wherein the first layer is formed from a first composition comprising an ethylene/a-olefin/diene interpolymer, an isoprene rubber (synthetic), a natural rubber, a butadiene rubber, a styrene butadiene rubber, a chloroprene rubber, a nitrile rubber, a hydrogenated nitrile rubber, a chlorinated polyethylene, a chlorosulfonated polyethylene, an ethylene/propylene rubber, an ethylene/diene copolymer, a fluoro rubber, a polyurethane, a silicone rubber, or a combination thereof; and wherein the second layer is formed from a second composition comprising a butyl rubber, a halobutyl rubber, polyvinylidene chloride, a brominated polymer derived from a copolymer of isobutylene and p-methyl styrene, a nitrile rubber, a chloroprene rubber, a chlorosulfonated polyethylene, a chlorinated polyethylene, a polyurethane, a fluoro rubber, or a combination thereof.