Polyethylene Laminate Gas Barrier Coating for Low-Temperature Drying
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Solution Overview
Problem
The production of composite films using polyethylene as a substrate requires improved drying properties and maintains gas barrier properties, as polyethylene has a lower melting point than polypropylene, necessitating lower drying temperatures and reduced adhesive application, which compromises gas barrier performance.
Innovation Solution
A laminate structure comprising a polyethylene-based first film, a gas barrier layer, and a polyolefin-based second film, where the gas barrier layer is formed from a coating composition containing a polyurethane resin derived from a reaction of a polyisocyanate component and a polyol component, with a controlled mass per unit area of 0.5 to 2.5 g/m², and bonded via an adhesive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the adhesive application amount is reduced to improve drying properties at lower temperatures, then drying properties are improved, but gas barrier properties are lowered
Solution Approach 1:
The invention changes the chemical composition parameters of the adhesive by incorporating specific polyol components (diols with 2-6 carbon atoms and active hydrogen group-containing compounds with hydrophilic groups) to enable effective drying at lower temperatures (below 100°C) while maintaining sufficient film formation to preserve gas barrier properties
Solution Approach 2:
The invention uses a composite adhesive system combining water-dispersible polyisocyanate with specially formulated polyol components creating a multi-functional coating that provides both adhesion and gas barrier properties at reduced application amounts and lower drying temperatures
2Productivity
If the adhesive application amount is reduced to improve drying properties, then drying properties are improved, but adhesive performance is compromised
Solution Approach 1:
The invention modifies the adhesive composition parameters to include specific polyol components that enhance drying efficiency and film formation at lower application amounts, enabling effective curing at reduced temperatures without sacrificing adhesive bonding strength
Solution Approach 2:
The invention optimizes the local chemical properties of the adhesive by incorporating hydrophilic group-containing compounds that improve water dispersibility and drying kinetics at the application interface, enabling faster drying at lower temperatures while maintaining bulk adhesive performance
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 drying properties at reduced temperatures, preventing heat damage to the polyethylene-based film while maintaining superior gas barrier properties.
Implementation Method 1
an isocyanate group-terminated prepolymer which is a reaction product of a polyisocyanate component and a polyol component
Implementation Method 2
a gas barrier layer, and a polyolefin-based second film in order, wherein the gas barrier layer is a coated and dried product
Data Source
Figure 1A~1D
AI summary
A laminate includes a polyethylene-based first film, a gas barrier layer, and a polyolefin-based second film in order. The gas barrier layer is a coated and dried product of a coating composition containing a main agent and a curing agent containing a water-dispersible polyisocyanate, the main agent containing a polyurethane dispersion containing a polyurethane resin which is a reaction product of an isocyanate group-terminated prepolymer which is a reaction product of a polyisocyanate component and a polyol component containing a diol having 2 to 6 carbon atoms and an active hydrogen group-containing compound having a hydrophilic group, and a chain extender. The mass per unit area of the coated and dried product is 0.5 g/m2 or more and 2.5 g/m2 or less.