Polyolefin Barrier Laminate for Retort-Resistant Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas barrier films for packaging materials, particularly those using polyolefin layers, suffer from deteriorated gas barrier properties and insufficient adhesion when subjected to high-temperature and high-humidity environments, such as retort treatments, due to inadequate abuse resistance and interlayer adhesion.
Innovation Solution
A laminate structure comprising a polyolefin substrate layer, an anchor coat layer with a specific elastic modulus and thickness range, and an inorganic barrier layer, enhanced with a polyurethane resin-based anchor coat agent, provides improved abuse resistance and adhesion, maintaining gas barrier properties under severe conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a polyolefin layer is used as the polymer film, then the packaging material has good recyclability, but the gas barrier properties deteriorate compared to polyester layers
Solution Approach 1:
The invention uses a composite structure consisting of a polyolefin substrate layer combined with an inorganic coating layer (silicon oxide, aluminum oxide, or silicon nitride) deposited by CVD. This composite material approach allows the packaging to maintain the recyclability of polyolefin while achieving superior gas barrier properties through the inorganic layer, resolving the contradiction between recyclability and gas barrier performance.
2Reliability
If a vapor deposited film with inorganic coating layer is used, then gas barrier properties improve, but adhesion between the polymer film and inorganic coating layer is insufficient
Solution Approach 1:
The invention changes the deposition parameters by using Chemical Vapor Deposition (CVD) instead of physical vapor deposition methods. This allows precise control over the inorganic coating layer formation, achieving both excellent gas barrier properties and strong adhesion to the polyolefin substrate. The CVD process enables the inorganic layer to bond effectively with the polymer surface while maintaining its barrier functionality.
3Ease of manufacture
If conventional packaging materials are used, then manufacturing is simple, but abuse resistance capable of maintaining gas barrier properties after severe treatment is insufficient
Solution Approach 1:
The invention creates a composite packaging structure with a polyolefin substrate layer and a CVD-deposited inorganic coating layer. This composite design provides excellent abuse resistance, maintaining gas barrier properties even after severe treatments like retort processing. The inorganic layer protects the polymer structure from degradation while the polyolefin base maintains manufacturability and recyclability.
4Adaptability or versatility
If a polyolefin substrate is used, then recyclability is improved, but interlayer adhesive force decreases after high-temperature and high-humidity treatment
Solution Approach 1:
The invention employs CVD technology to deposit the inorganic coating layer under controlled chemical vapor conditions. This deposition method creates strong chemical bonds between the inorganic layer and the polyolefin substrate that remain stable after high-temperature and high-humidity treatments. The parameter control in CVD ensures the inorganic layer adheres firmly to the polyolefin, preventing delamination during severe processing while preserving the recyclability of the polyolefin base material.
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 maintains excellent gas barrier properties and interlayer adhesion even after severe treatments, ensuring durability and reliability of packaging materials.
Implementation Method 1
gas barrier properties that blocks ingress of oxygen, water vapor, and other gases
Implementation Method 2
vapor deposited film in which an inorganic coating layer of silicon oxide, aluminum oxide, or the like is formed as a gas barrier layer on a polymer film by a vacuum deposition method
Implementation Method 3
vapor deposited film in which an inorganic coating layer of silicon oxide, aluminum oxide, or the like is formed as a gas barrier layer on a polymer film by a sputtering method
Data Source
AI summary
There is provided a laminate excellent in abuse resistance and adhesion, and a packaging material, a package, and a packaged article including the laminate. The laminate (10) includes a first substrate layer (1), an anchor coat layer (2), and an inorganic barrier layer (3) in this order, wherein the first substrate layer (1) contains a polyolefin, and the anchor coat layer (2) has a sectional composite elastic modulus in a range of 3.5 to 6.5 GPa and a thickness in a range of 0.4 to 3.0 μm.