Oxidized Resin Laminate for VOC-Free Packaging Bonding
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Solution Overview
Problem
Existing resin laminates used in packaging containers generate volatile organic compounds (VOCs) during production and often have insufficient peel strength when produced without adhesives or anchor coating agents.
Innovation Solution
A resin laminate configuration comprising a first layer, a second layer, and an intermediate layer, where the surfaces in contact are oxidized, and the intermediate layer is made of polyethylene with a density of 0.915 g/cm3 or less, using thermoplastic resins and cellophane, and a production method involving atmospheric pressure plasma treatment and ozone treatment to laminate the films without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive or anchor coating agent is used to laminate resin films, then peel strength between resin films is sufficiently increased, but volatile organic compounds (VOC) are generated during the production process
Solution Approach 1:
The patent removes the adhesive layer from the laminate structure, extracting the harmful VOC-generating component while maintaining peel strength through surface oxidation treatments and controlled intermediate layers made of polyethylene with density of 0.915 g/cm³ or less
Solution Approach 2:
The patent changes the physical and chemical parameters of the resin films by applying oxidation treatments (such as plasma treatment or ozone treatment) to modify surface properties, and by controlling the density parameter of the intermediate layer material to achieve adequate adhesion without adhesives
2Strength
If an adhesive or anchor coating agent is used to laminate resin films, then peel strength between resin films is sufficiently increased, but the production process becomes more complex and costly
Solution Approach 1:
The patent eliminates the adhesive application process, coating drying process, and associated quality control steps, thereby simplifying the production process while maintaining peel strength through physical and chemical surface modifications
3Object-generated harmful factors
If resin films are laminated without adhesive or anchor coating agent, then VOC emissions are avoided, but peel strength between resin films becomes insufficient
Solution Approach 1:
The patent applies oxidation treatments (plasma or ozone) to the resin film surfaces before lamination, performing preliminary surface modification to enhance reactivity and adhesion potential, which enables strong bonding without subsequent adhesive application
Solution Approach 2:
The patent introduces an intermediate layer made of polyethylene with density of 0.915 g/cm³ or less as a mediator between resin films, which facilitates adhesion through its oxidized surface while avoiding the use of harmful adhesive chemicals
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 laminate achieves sufficient peel strength without VOC emissions, suitable for packaging containers, and the production method ensures peel strength while avoiding VOC generation.
Implementation Method 1
a step of subjecting a surface of the first film to atmospheric pressure plasma treatment under a nitrogen atmosphere or a mixed atmosphere of nitrogen and hydrogen
Implementation Method 2
a surface of the first layer in contact with the intermediate layer is an oxidized surface
Implementation Method 3
while at least the surface of the molten resin film in contact with the first film is subjected to ozone treatment
Implementation Method 4
at least a surface of the intermediate layer in contact with the first layer is an oxidized surface
Implementation Method 5
the molten resin film is melt-extruded between the first film and the second film and continuously laminated
Implementation Method 6
a surface of the first layer in contact with the intermediate layer is an oxidized surface, at least a surface of the intermediate layer in contact with the first layer is an oxidized surface
Data Source
AI summary
There is provided a resin laminate including: at least a first layer; a second layer; and an intermediate layer laminated in contact with the first layer and the second layer, in which a surface of the first layer in contact with the intermediate layer is an oxidized surface, a surface of the intermediate layer in contact with the first layer is an oxidized surface, the first layer is a layer in which a thermoplastic resin is used as a forming material or a layer in which cellophane is used as a forming material, and the intermediate layer is made of polyethylene having a density of 0.915 g/cm3 or less.