Polyester Base Layer Titanium Dioxide Coating Delamination Resistance
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Solution Overview
Problem
Conventional multi-layer cards are susceptible to delamination, which reduces their durability, security, and tamper-resistance, and the plane of failure often occurs within the polyester base layer, indicating a need to enhance the cohesive strength of this layer.
Innovation Solution
Incorporating titanium dioxide particles coated with an organic coating, such as an organophosphorus compound or a polymeric coating without silicon atoms, into the polyester base layer to improve the delamination resistance and cohesive strength of the multi-layer film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-layer cards are constructed with polyester base layer and copolyester heat-sealable layer, then the card can be manufactured with standard materials and processes, but the card is susceptible to delamination which reduces durability and security
Solution Approach 1:
The patent modifies the chemical composition parameters of the polyester base layer by incorporating specific additives (silane-modified polyester, titanium dioxide with organic coating) and adjusting molecular weight and composition ratios. These parameter changes enhance the cohesive strength and delamination resistance of the base layer without fundamentally changing the manufacturing process or material types, thus improving reliability while maintaining ease of manufacture
Solution Approach 2:
The patent creates a composite polyester base layer by combining multiple materials: conventional polyester, silane-modified polyester (1-20 wt%), and titanium dioxide particles with organic coating (0.1-10 wt%). This composite structure leverages the complementary properties of each component to achieve superior delamination resistance and cohesive strength while remaining compatible with existing manufacturing processes
2Reliability
If the polyester base layer is made more cohesive to prevent delamination, then delamination resistance improves, but the optical properties such as opacity and whiteness may be affected
Solution Approach 1:
The patent carefully controls the concentration parameters of additives in the polyester base layer. The silane-modified polyester is limited to 1-20 wt% and titanium dioxide with organic coating to 0.1-10 wt%. These controlled parameter changes allow sufficient cohesive strength enhancement while maintaining the optical properties required for card visibility and design
Solution Approach 2:
The patent uses titanium dioxide particles with organic coating as an intermediary substance that serves dual functions: the titanium dioxide core provides opacity and whiteness (optical properties), while the organic coating enhances the cohesive strength of the polyester matrix. This intermediary approach allows simultaneous improvement of both mechanical and optical properties without compromise
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 enhanced multi-layer films exhibit superior delamination resistance and improved security and tamper-resistance while maintaining excellent optical properties like opacity and whiteness.
Implementation Method 1
the particles are coated with an organic coating
Implementation Method 2
maintaining excellent optical properties such as high opacity, high whiteness and low yellowness
Data Source
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AI summary
A muiti-iayer film comprising: (i) a polyester base layer (B) having a first and second surface wherein the polyester of the base layer is a crystals isabie polyester; and (ii) a heat-sealabie copolyester Iayer (A) disposed on one or both surfaces of said polyester base layer (B); wherein the polyester base iayer (S) comprises titanium dioxide particles in an amount of from about 1 to about 30 wt% by total weight of the base iayer, wherein said particles are coated with an organic coating; and a muiii-layer card comprising said muiii-layer film, a polymeria inlay layer and a polymeric overlay layer such that the layer order is poiymeric inlay iayer, first multi-layer film and first polymeric overlay layer.