Plasma-Treated Multilayer Body for Direct Extrusion Lamination
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Solution Overview
Problem
Existing methods for extrusion lamination of thermoplastic resins onto plastic substrates face challenges with poor adhesiveness, requiring anchor coatings or ozonation, which are costly, environmentally problematic, and increase production complexity.
Innovation Solution
The method involves plasma treatment of the substrate and gas barrier coating layer, using reactive ion etching and X-ray photoelectron spectroscopy to optimize surface functional groups, allowing direct extrusion lamination of thermoplastic resins without anchor coatings or ozonation, enhancing adhesiveness between the resin and substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an anchor coating agent is applied to the plastic film before extrusion lamination, then adhesiveness between the thermoplastic resin and substrate is improved, but production costs increase and environmental problems arise due to organic solvent use
Solution Approach 1:
The invention extracts and eliminates the anchor coating agent step from the lamination process. By using plasma treatment to directly modify the substrate surface, the patent removes the need for separate coating applications, solvent drying, and anchor agent materials, thereby reducing production costs and environmental impact while maintaining adhesion improvement
Solution Approach 2:
The invention replaces the chemical mechanism of anchor coating agents with a physical plasma treatment mechanism. Plasma treatment uses ionized gas to directly modify substrate surface properties, substituting the chemical bonding approach with a physical surface activation approach that achieves similar adhesion enhancement without organic solvents
2Strength
If an anchor coating agent is applied to both sides of the plastic film, then adhesiveness on both sides is improved, but the number of production steps increases when using conventional facilities
Solution Approach 1:
The invention makes the plasma treatment apparatus universal by enabling it to treat both sides of the substrate sequentially. The same plasma generation unit that treats one side can subsequently treat the other side, making the equipment multi-functional and eliminating the need for separate coating facilities for each side
3Strength
If ozonation is applied to the thermoplastic resin during extrusion lamination, then adhesiveness is improved, but safety concerns arise due to ozone toxicity and bad smell
Solution Approach 1:
The invention introduces plasma as an intermediary treatment between the substrate and thermoplastic resin. Instead of using ozone gas that contacts the resin during extrusion, plasma treatment pre-modifies the substrate surface in a controlled manner, acting as an intermediary that achieves adhesion enhancement without introducing toxic substances into the extrusion process
4Strength
If a printed layer is disposed on the substrate and surface-treated with UV rays before extrusion lamination, then adhesiveness is improved, but production costs and steps increase for constitutions not requiring printed layers
Solution Approach 1:
The invention extracts the printed layer step from the process sequence. By applying plasma treatment directly to the substrate surface without requiring a printed layer intermediary, the patent eliminates unnecessary steps for applications where printing is not required, while still achieving effective surface modification and adhesion enhancement
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
This approach achieves strong adhesiveness between the thermoplastic resin and substrate, reducing production costs and environmental concerns while simplifying the lamination process, applicable to various packaging materials.
Implementation Method 1
a method of manufacturing a laminate which exhibits strong interlaminar adhesiveness upon extrusion lamination of a thermoplastic resin onto a plastic film or a substrate including a plastic film
Implementation Method 2
The method involves plasma treatment of the substrate and gas barrier coating layer, using reactive ion etching and X-ray photoelectron spectroscopy to optimize surface functional groups
Implementation Method 3
The method involves plasma treatment of the substrate and gas barrier coating layer, using reactive ion etching and X-ray photoelectron spectroscopy to optimize surface functional groups
Implementation Method 4
the extrusion lamination advantageous in cost and efficiency is widely used
Implementation Method 5
a method of manufacturing a laminate which exhibits strong interlaminar adhesiveness upon extrusion lamination of a thermoplastic resin onto a plastic film or a substrate including a plastic film
Data Source
Figure 1~2
AI summary
A laminate prepared by pretreating at least one side of a substrate of a plastic film by plasma treatment and then directly laminating a thermoplastic resin on a surface treated by pretreatment.