Polyepoxy Adhesive Laminate for Gas Barrier Packaging

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Solution Overview

Problem

Existing laminates with gas barrier layers face issues with bubble formation due to carbon dioxide generation during adhesive curing, leading to defects in external appearance and potential delamination, and require additional surface protective layers that increase costs and limit material options.

Innovation Solution

A laminate configuration with a polyepoxy resin-based adhesive layer between gas barrier layers, combined with a polyisocyanate-based adhesive layer that generates carbon dioxide, allows for its release through non-gas barrier layers, preventing bubble formation and eliminating the need for a surface protective layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a two-component reaction polyurethane-based adhesive is used between gas barrier layers, then adhesive strength is improved, but carbon dioxide bubbles form causing external appearance defects

Engineering Contradiction:

Improveinterlayer adhesive strengthVSAvoidcarbon dioxide bubble formation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent segments the adhesive system into two distinct components: a polyol component applied to the first gas barrier layer and a polyisocyanate component applied to the second gas barrier layer. This segmentation allows the adhesive layers to be applied separately and cured in a controlled manner, preventing carbon dioxide bubbles from forming within the laminate while still achieving strong interlayer bonding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent extracts the harmful carbon dioxide generation issue by using a polyepoxy resin-based adhesive instead of a two-component reaction polyurethane-based adhesive. The polyepoxy resin system does not generate carbon dioxide during curing, thereby eliminating the bubble formation problem while maintaining adequate adhesive strength for bonding gas barrier layers.

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-affected harmful factors

If the first gas barrier layer is arranged with the non-vapor-deposited side contacting the adhesive, then carbon dioxide can be absorbed or released, but the thin inorganic film may peel off requiring a surface protective layer

Engineering Contradiction:

Improvecarbon dioxide absorption/releaseVSAvoidthin inorganic film adhesion

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent inverts the conventional arrangement by placing the vapor-deposited side of the first gas barrier layer in contact with the adhesive layer instead of the non-vapor-deposited side. This inversion ensures that the thin inorganic film remains on the outer surface where it provides gas barrier functionality, while the adhesive bonds to the resin substrate beneath, preventing film peeling without requiring an additional protective layer.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If a surface protective layer is provided on the thin inorganic film to suppress peeling, then film adhesion is improved, but cost increases and material options are limited

Engineering Contradiction:

Improvethin inorganic film adhesionVSAvoidlaminate structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the need for a surface protective layer by correctly orienting the gas barrier layer during lamination. By placing the vapor-deposited side in contact with the adhesive, the thin inorganic film naturally adheres to the laminate structure through its bonding to the resin substrate, achieving film stability without adding extra layers or increasing complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent makes the gas barrier layer multi-functional by having it serve both as a gas barrier and as an adhesive substrate. The vapor-deposited side provides gas barrier functionality while also serving as the bonding interface with the adhesive layer, eliminating the need for separate protective layers and reducing overall laminate complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 excellent gas barrier properties without bubble formation and external defects, suitable for packaging materials like hydrogenous water containers, with enhanced interlayer adhesive strength and cost-effectiveness.

Implementation Method 1

at least one adhesive layer (X) formed of an adhesive (x) having a polyepoxy resin as a main ingredient and a polyamine resin as a curing agent is provided between an arbitrary gas barrier layer and another gas barrier layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

a polyisocyanate-based adhesive layer that generates carbon dioxide, allows for its release through non-gas barrier layers

Methodology Applied

Scientific EffectChemical reaction: Reaction (physics)

Data Source

PatentUS10773491B2Laminate, packaging bag, packaging bag with plug, and packaging bag with plug with hydrogenous-water

Publication Date: 2020.09.15 HOSOKAWA YOKO CO LTD

AI summary

The present invention provides a laminate (10A) having a first gas barrier layer (11) formed of a gas barrier transparent resin film and a second gas barrier layer (12) formed of a metal foil, in which at least one adhesive layer (X) (21) formed of an adhesive (x) including a polyepoxy resin as a main ingredient and a polyamine resin as a curing agent is provided between the first gas barrier layer (11) and the second gas barrier layer (12).