Organic Barrier Layer Transfer via Release Agent
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Solution Overview
Problem
Existing methods for enhancing barrier properties on substrates with irregular surface topology and flexible materials, such as cellulose-based papers and polyolefins, are inadequate, and traditional barrier materials like aluminum foil and polyvinylidene chloride pose environmental challenges due to recyclability and incineration issues.
Innovation Solution
A method involving a multilayer structure with an organic barrier layer, adhesive layer, and substrate, using a carrier film with a release agent to transfer a crystalline organic compound like melamine onto substrates, including biodegradable or polyolefin materials, via vacuum deposition or liquid coating, ensuring minimal environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional barrier materials like aluminum foil and polyvinylidene chloride are used, then barrier properties are improved, but environmental impact worsens due to incineration residues and dioxin generation
Solution Approach 1:
The invention changes the material composition parameter from traditional aluminum foil and polyvinylidene chloride to organic barrier materials such as polyvinyl alcohol and ethylene-vinyl alcohol copolymer. This parameter change maintains barrier effectiveness while eliminating the harmful incineration residues and dioxin generation associated with traditional materials, directly resolving the environmental impact issue.
Solution Approach 2:
The invention uses composite material structures where organic barrier layers are applied on carrier films with release agents. This composite approach allows the barrier functionality to be achieved through material composition rather than relying on aluminum or PVdC, thereby maintaining barrier properties while eliminating the environmental harm from incineration.
2Ease of manufacture
If barrier layers are directly applied on substrates with irregular surface topology, then the process is simplified, but barrier performance deteriorates due to defects in the barrier layer
Solution Approach 1:
The invention introduces a carrier film with a release agent as an intermediary between the substrate and the organic barrier layer. The release agent layer mediates the interface, allowing the barrier layer to be formed defect-free on the carrier film surface and then transferred to the substrate, thereby maintaining high barrier performance even on substrates with irregular surface topology.
Solution Approach 2:
The invention performs preliminary action by first forming the barrier layer on the carrier film with release agent before transferring it to the final substrate. This preliminary formation on a controlled carrier film surface ensures defect-free barrier layer creation, which is then transferred to the substrate, maintaining barrier performance regardless of the substrate's surface topology.
3Object-generated harmful factors
If plastics are replaced by biopolymers and bio-based materials for environmental reasons, then recyclability is improved, but barrier properties deteriorate
Solution Approach 1:
The invention creates composite structures by applying organic barrier layers on biopolymer and bio-based plastic substrates. This composite approach combines the environmental benefits of biodegradable substrates with the barrier properties of organic barrier materials, thereby achieving both improved recyclability and maintained barrier performance.
Solution Approach 2:
The invention changes the material parameters by selecting specific organic barrier materials such as polyvinyl alcohol and ethylene-vinyl alcohol copolymer that provide effective barrier properties. When applied on biopolymer substrates, these materials maintain barrier effectiveness while the substrate provides improved recyclability and environmental compatibility.
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 process achieves high-quality barrier properties on diverse substrates, including cellulose-based materials and flexible polymers, with improved recyclability and reduced environmental burden, maintaining or enhancing barrier performance.
Implementation Method 1
a release agent chosen from (i) an organic release layer, which organic release layer has the capacity to effect a releasable bond from the surface of the carrier film and a non-releasable bond with the surface of an organic barrier layer
Implementation Method 2
The organic barrier layer preferably is applied by vacuum deposition
Implementation Method 3
The organic barrier layer preferably is a crystalline organic compound, and most preferably melamine
Data Source
AI summary
The invention relates to a method for producing a multilayer structure comprising an organic barrier layer, adhesive layer and substrate, comprising the following steps (a) providing a carrier film, (b) wherein a major part of the surface of the carrier film is provided with a release agent chosen from (i) an organic release layer, which organic release layer has the capacity to effect a releasable bond from the surface of the carrier film and a non-releasable bond with the surface of an organic barrier layer to be applied on the release layer and/or (ii) a metal layer on the carrier film which adheres stronger to the carrier film than to the organic barrier layer, (c) providing an organic barrier layer on the release agent, (d) providing an adhesive layer on the organic barrier layer, and bonding the organic barrier layer with said adhesive to a substrate, and (e) stripping said carrier film from the multilayer structure.