Paper Barrier Laminate with Moisture-Stable Gas Barrier Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing paper-made barrier materials face issues with waterproofness and degradation of water-soluble polymer-containing gas barrier layers due to moisture penetration, leading to increased layer complexity and production steps.
Innovation Solution
A barrier laminate with a paper substrate, featuring a gas barrier layer containing specific resin binders and a water vapor barrier layer with a layered inorganic compound, cationic resin, and water-dispersible resin binder, which enhances both water vapor and gas barrier properties while maintaining economic potential and reducing layer count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water-soluble polymer-containing gas barrier layer is formed on a paper substrate, then gas barrier properties are improved, but the layer is readily degraded by moisture in the paper substrate and air
Solution Approach 1:
The gas barrier layer uses a composite structure combining water-soluble polymer (polyvinyl alcohol) with water-dispersible polymer (urethane resin or vinylidene chloride resin). This composite material maintains the gas barrier properties of the water-soluble polymer while the water-dispersible polymer component provides moisture resistance and prevents degradation by the paper substrate and air.
2Reliability
If an additional laminate layer is added to secure waterproofness, then waterproofness is improved, but the number of layers and production steps increases
Solution Approach 1:
The water vapor barrier layer is designed to perform multiple functions simultaneously: it provides waterproofness, serves as a protective layer for the gas barrier layer, and acts as an adhesive barrier. By making this single layer multi-functional, the patent eliminates the need for separate laminate layers, reducing overall structural complexity while maintaining waterproofness.
3Stability of the object's composition
If a protective layer is added to protect the gas barrier layer, then stability is improved, but the number of layers and production steps increases
Solution Approach 1:
The patent merges the protective layer and water vapor barrier layer into a single integrated layer. This water vapor barrier layer simultaneously protects the gas barrier layer from moisture degradation and provides waterproofness, eliminating the need for separate protective layers and reducing production complexity.
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 provides excellent water vapor and gas barrier properties with waterproofness, improved coating performance, and reduced environmental impact, while minimizing the number of layers and production steps.
Implementation Method 1
a water vapor barrier layer containing a layered inorganic compound, a cationic resin and a water-dispersible resin binder
Implementation Method 2
the gas barrier layer contains a water-soluble polymer and a water-dispersible resin binder
Implementation Method 3
a water vapor barrier layer containing a layered inorganic compound, a cationic resin and a water-dispersible resin binder
Data Source
AI summary
A barrier laminate having a paper substrate and, on at least one surface of the paper substrate, a gas barrier layer and a water vapor barrier layer in that order, wherein the gas barrier layer contains at least one selected from the group consisting of a water-soluble resin binder and a water-dispersible resin binder 1, the water vapor barrier layer contains a layered inorganic compound, a cationic resin and a water-dispersible resin binder 2, the water-dispersible resin binder 1 and the water-dispersible resin binder 2 are not the same, the layered inorganic compound has an aspect ratio of 50 or more, the layered inorganic compound has a thickness of 50 nm or less, the content of the layered inorganic compound in the water vapor barrier layer is 0.1 parts by mass or more and 100 parts by mass or less relative to 100 parts by mass of the water-dispersible resin binder 2.