Atmospheric Plasma Treated Laminate Bonding Without Adhesives
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Solution Overview
Problem
Conventional laminate production methods using bonding agents or anchor coating agents result in insufficient bond strength, VOC emissions, and contamination risks, failing to achieve superior environmental and energy conservation performance.
Innovation Solution
A laminate production method that thermocompression-bonds substrates without using a bonding agent or anchor coating agent, employing surface modification with atmospheric pressure plasma treatment to form heat-bonding layers on polyethylene terephthalate, polyamide, and other thermoplastic resin films, ensuring strong interlayer bonding and eliminating VOC emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bonding agents or anchor coating agents are used in laminate production, then interlayer bonding strength is improved, but VOC emissions occur and environmental performance deteriorates
Solution Approach 1:
The invention extracts and removes the harmful bonding agents and anchor coating agents from the laminate production process entirely. By using surface-modified films with plasma-treated surfaces, the patent achieves interlayer bonding without any adhesive substances, thereby eliminating VOC emissions completely while maintaining strong bonding between layers.
Solution Approach 2:
The invention introduces surface modification treatment (plasma treatment) as an intermediary process that prepares the film surfaces for bonding. This surface treatment creates reactive groups and improves surface energy, enabling direct thermocompression bonding between layers without requiring chemical adhesives, thus resolving the contradiction between bonding strength and environmental harm.
2Strength
If bonding agents or anchor coating agents are used in laminate production, then interlayer bonding strength is improved, but contamination risk increases
Solution Approach 1:
The invention removes bonding agents and anchor coating agents from the production process, eliminating the source of low molecular components that could contaminate packaged contents. The surface-modified films bond directly through thermocompression, preventing any chemical contamination risk while maintaining adequate bonding strength.
3Ease of manufacture
If conventional laminate production methods are used, then manufacturing process is simple, but environmental handling performance is poor
Solution Approach 1:
The invention performs surface modification treatment on films before lamination, creating pre-active surfaces that enable direct bonding without adhesives. This preliminary action simplifies the overall manufacturing process by eliminating adhesive application and drying steps, while simultaneously improving environmental performance by removing VOC-emitting chemicals.
4Ease of manufacture
If conventional laminate production methods are used, then manufacturing process is simple, but energy conservation performance is poor
Solution Approach 1:
The invention extracts the energy-intensive drying and curing processes from conventional laminate production by eliminating adhesive substances entirely. The surface-modified films bond through direct thermocompression at lower temperatures and without requiring energy-intensive evaporation or curing steps, thereby improving energy conservation performance while maintaining manufacturing simplicity.
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 method achieves strong interlayer bonding without VOC emissions or contamination, providing superior environmental handling and energy conservation performance, suitable for various packaging applications, including liquid products and sensitive components.
Implementation Method 1
surface modification with atmospheric pressure plasma treatment to form heat-bonding layers on polyethylene terephthalate, polyamide, and other thermoplastic resin films
Implementation Method 2
the substrates are thermocompression-bonded by a heated roller to be continuously laminated
Data Source
Figure 1~2
Figure 3~4B
Figure 5A~5B
AI summary
A substrate which is either a first substrate (1) or a second substrate (6) consisting of a different kind of thermoplastic resin film or cellophane film, and which is drawn out from rolled films (21, 22) where the first substrate and the second substrate are rolled respectively. The substrate has a surface of the hot gluing reforming layer which was formed with the surface modification with an atmospheric pressure plasma processor (23), and the other substrate (8) has a surface with which an air corona processor (24) is possessed. And the substrate and the other base member are opposed, and are attached together with a heating roll (25) with spreading neither an adhesive nor an anchor agent.